U.S. patent application number 11/299104 was filed with the patent office on 2006-08-10 for films from polymer blends.
Invention is credited to Sudhin Datta, Srivatsan Srinivas Iyer, Wen Li, Aspy K. Mehta.
Application Number | 20060178483 11/299104 |
Document ID | / |
Family ID | 36090515 |
Filed Date | 2006-08-10 |
United States Patent
Application |
20060178483 |
Kind Code |
A1 |
Mehta; Aspy K. ; et
al. |
August 10, 2006 |
Films from polymer blends
Abstract
This invention relates to a film comprising a heterogeneous
blend of: 1) from 60 to 99 wt % of one or more semi-crystalline
polymers; and 2) from 1 to 40 wt % of one or more semi-amorphous
polymers; where the bend has: an MFR of 0.5 to 100 dg/min, a haze
of 20% or less, and a permanent set of greater than 65%; and where
the film is 2.5 to 635 microns thick and has: a haze of 10% or
less, a 1.degree. Secant tensile modulus of 100,000 to 30,000 psi,
an Elmendorf tear in the machine direction and transverse direction
of 45 g/mil or more, a total energy impact of 3 J or more; and a 45
degree gloss of 82 or more.
Inventors: |
Mehta; Aspy K.; (Humble,
TX) ; Datta; Sudhin; (Houston, TX) ; Li;
Wen; (Houston, TX) ; Iyer; Srivatsan Srinivas;
(Pearland, TX) |
Correspondence
Address: |
EXXONMOBIL CHEMICAL COMPANY
5200 BAYWAY DRIVE
P.O. BOX 2149
BAYTOWN
TX
77522-2149
US
|
Family ID: |
36090515 |
Appl. No.: |
11/299104 |
Filed: |
December 9, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60637429 |
Dec 17, 2004 |
|
|
|
60655310 |
Feb 22, 2005 |
|
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Current U.S.
Class: |
525/240 |
Current CPC
Class: |
Y10T 428/249924
20150401; C08L 2666/06 20130101; C08L 2666/06 20130101; C08L
2666/06 20130101; C08L 23/142 20130101; C08L 23/10 20130101; Y10T
428/31645 20150401; Y10T 428/31692 20150401; C08L 2205/025
20130101; C08L 23/14 20130101; Y10T 428/31895 20150401; C08L 23/142
20130101; C08L 2205/02 20130101; Y10T 428/31913 20150401; C08L
23/14 20130101; C08L 23/10 20130101 |
Class at
Publication: |
525/240 |
International
Class: |
C08L 23/04 20060101
C08L023/04 |
Claims
1. A film comprising a heterogeneous blend of: 1) from 60 to 99
weight percent of one or more semi-crystalline polymers (based upon
the weight of the semi-crystalline and semi-amorphous polymers),
each semi-crystalline polymer comprising propylene and from 0 to 5
weight % alpha-olefin comonomer (based upon the weight of the
polymer), said semi-crystalline polymers each having a melting
point between 100 and 170.degree. C. and a melt flow rate of 200
dg/min or less; and 2) from 1 to 40 weight % of one or more
semi-amorphous polymers (based upon the weight of the
semi-crystalline and semi-amorphous polymers), each semi-amorphous
polymer comprising propylene and from 10 to 25 weight % of one or
more C2 and or C4 to C10 alpha-olefin comonomers, said
semi-amorphous polymers each having: a) heat of fusion of 4 to 70
J/g; b) a melt flow rate of 0.1 to 200 dg/min; c) an intermolecular
composition distribution as determined by thermal fractionation in
hexane such that 85% by weight or more of the polymer is isolated
as one or two adjacent, soluble fractions with the balance of the
polymer in immediately preceding or succeeding fractions; and
wherein each of these fractions has a wt % comonomer content with a
difference of no greater than 20 wt % relative to the average wt %
comonomer content of the copolymer; d) an Mw/Mn of 1.5 to 4, e) a
propylene triad tacticity, as measured by .sup.13C NMR, of 75% or
greater; where the blend has: i) a melt flow rate of 0.5 to 100
dg/min; and ii) 0 to 5 weight % filler, based upon the weight of
the polymers and the filler; and iii) a haze of 20% or less
measured on a 1 mm thick injection molded chip; and iv) a permanent
set of greater than 65%; and where the film is 0.1 to 25 mil (2.5
to 635 micron) thick and has: a haze of 10% or less, a 1.degree.
Secant tensile modulus of 100,000 to 30,000 psi, an Elmendorf tear
in the machine direction of 45 g/mil or more, an Elmendorf tear in
the transverse direction of 45 g/mil or more, a total energy impact
of 3 J or more; and a 45 degree gloss of 82 or more.
2. The film of claim 1 wherein the semi-crystalline polymer
comprises propylene and from 1 to 3 weight % of a C2 to C10 alpha
olefin comonomer.
3. The film of claim 2 wherein the alpha-olefin comonomer is
selected from the group consisting of ethylene, butene, pentene,
hexene, heptene, octene, nonene, and decene.
4. The film of claim 2 wherein the alpha-olefin comonomer is
selected from the group consisting of ethylene, butene, hexene, and
octene.
5. The film of claim 2 wherein the alpha-olefin comonomer is
ethylene.
6. The film of claim 1 wherein the semi-crystalline polymer
comprises 0 weight % comonomer.
7. The film of any of the above claims wherein the semi-crystalline
polymer has a melting point of 120 to 170.degree. C.
8. The film of claim 1 wherein the semi-crystalline polymer has an
Mw/Mn between 1.5 and 4.
9. The film of claim 1 wherein the semi-amorphous polymer comprises
propylene and from 10 to 20 weight % of a C2 to C10 alpha olefin
comonomer.
10. The film of claim 9 wherein the alpha-olefin comonomer is
selected from the group consisting of ethylene, butene, pentene,
hexene, heptene, octene, nonene, and decene.
11. The film of claim 9 wherein the alpha-olefin comonomer is
selected from the group consisting of ethylene, butene, hexene, and
octene.
12. The film of claim 9 wherein the alpha-olefin comonomer is
ethylene.
13. The film of claim 1 wherein the semi-amorphous polymer has a
percent crystallinity of between 2 and 25%.
14. The film of claim 1 wherein the semi-amorphous polymer has a
melt flow rate of 1 to 25 dg/min.
15. The film of claim 1 wherein the semi-amorphous polymer has a
melting point between 30 and 80.degree. C.
16. The film of claim 1 wherein the semi-amorphous polymer has a
tacticity index of from 4 to 12.
17. The film of claim 1 wherein the semi-amorphous polymer has a
propylene triad tacticity of 80% or greater.
18. The film of claim 1 wherein the semi-amorphous polymer has a
propylene triad tacticity of 85% or greater.
19. The film of claim 1 where the blend has a haze of 15% or
less.
20. The film of claim 1 where the blend has a haze of 12% or
less.
21. The film of claim 1 wherein the blend has a haze of 10% or
less.
22. The film of claim 1 where the film has a gloss of 85 units or
more.
23. The film of claim 1 wherein the semi-amorphous polymer
comprises from 11 to 25 weight % comonomer and is present at from
15 to 40 weight %, and wherein the blend has dispersions of
semi-amorphous polymer less than 4 .mu.m in size in a continuous
phase of semi-crystalline polymer and wherein the film has machine
direction Elmendorf tear of 60 g/mil (2.4 g/.mu.m) or more, haze of
2% or less, 45 degree gloss of 87 unit or higher, 1% secant tensile
modulus of 75,000 psi (517 MPa) or lower, and total energy impact
of 3 J or more.
24. The film of claim 1 wherein the semi-amorphous polymer
comprises from 11 to 25 weight % comonomer and is present at from
25 to 40 weight %, and wherein the blend has dispersions of
semi-amorphous polymer less than 4 .mu.m in size in a continuous
phase of semi-crystalline polymer and wherein the film has machine
direction Elmendorf tear of 100 g/mil (2.4 g/.mu.m) or more, haze
of 1.5% or less, 45 degree gloss of 88 unit or higher, 1% secant
tensile modulus of 50,000 psi (517 MPa) or lower, and total energy
impact of 7 J or more.
25. The film of claim 1 wherein the blend has a permanent set of
165% or more.
26. The film of claim 1 wherein the blend has a permanent set of
175% or more.
27. The film of claim 1 wherein the blend has a permanent set of
200% or more.
28. The film of claim 1 wherein a 3.18 mm thick injection molded
pad of the blend has a resistance to stress whitening of Hunter
color .DELTA.L of 20 or less.
29. The film of claim 1 wherein the film has a haze of 4% or
less.
30. The film of claim 1 wherein the film has a haze of 3% or
less.
31. The film of claim 1 wherein the film has a haze of 2% or
less.
32. The film of claim 28 wherein the film has a haze of 5% or less,
an MD Elmendorf tear of 50 g/mil or more and a total energy impact
of 3 J or more.
33. The film of claim 28 wherein the film has a haze of 2% or less,
an MD Elmendorf tear of 100 g/mil or more and a total energy impact
of 7 J or more.
34. The film of claim 33 wherein the film has a 45.degree. gloss of
85 units or more.
35. The film of claim 1 wherein the film has a 45.degree. gloss of
90 units or more.
36. The film of claim 1 wherein the film has: a) a haze of 2% or
less; b) a machine direction tensile strength at break of greater
than 40 MPa; c) a transverse direction tensile strength at break of
greater than 40 MPa; d) a machine direction elongation at break of
greater than 500%; e) a transverse direction elongation at break of
greater than 500%; f) a machine direction Elmendorf tear of 50 to
150 g/mil; g) a transverse direction Elmendorf tear of 100 to 400
g/mil; h) a puncture resistance of 6 to 10 lb/mil; and i) a machine
direction tensile modulus of less than 350 MPa.
37. The film of claim 1 where the film is a cast film.
38. The film of claim 1 where the film is a blown film.
39. The film of claim 1 where the film is a laminated film.
40. The film of claim 1 wherein the film is coextruded.
41. The film of claim 1 wherein the film is laminated.
42. The film of claim 1 wherein the film comprises two or more
layers.
43. The film of claim 1 wherein the film comprises a core layer
comprising the heterogeneous blend.
44. The film of claim 1 wherein the film comprises a skin layer
comprising the heterogeneous blend.
45. The film of claim 1 wherein the blend of the semi-amorphous and
semi-crystalline polymers further comprises plasticizer.
46. The film of claim 45 wherein the plasticizer comprises
poly-alphaolefin.
47. The film of claim 46 wherein the poly-alphaolefin comprises
polydecene.
48. The film claim 1 wherein the heterogeneous blend further
comprises slip agent.
49. The film of claim 48 wherein the slip agent comprises 50 to
5000 ppm of an amides having the chemical structure
CH.sub.3(CH.sub.2).sub.7CH.dbd.CH(CH.sub.2).sub.xCONH.sub.2 where x
is 5 to 15.
50. The film of claim 1 wherein the heterogeneous blend further
comprises from 10 ppm to 10 weight % of a clarifying agent.
51. The film of claim 50 wherein the clarifying agent comprises 50
to 4000 ppm of an organophosphate, phosphate ester, sodium
benzoate, talc, sorbitol, adipic acid, benzoic acid, a metal salts
of adipic acid, a metal salt of benzoic acid, an inorganic fillers,
or a Ziegler-Natta olefin product or other highly crystalline
polymers.
52. The film of claim 50 wherein the clarifying agent comprises 50
to 4000 ppm of a sorbitol-based agent, an aluminum salt based
agent, or a sodium salt based agent.
53. The film of claim 50 wherein the clarifying agent comprises 50
to 4000 ppm of disodium[2.2.1]heptane bicyclodicarboxylate, bis(3,4
dimethylbenzylidene)sorbitol, sodium
2,2'-methylene-bis(4,6-di-tert-butylphenyl) phosphate, (p-chloro,
p'methyl)dibenzylidene sorbitol, bis(p-ethylbenzylidene)sorbitol,
1,2,3,4-dibenzylidene sorbitol, 1,2,3,4-di-para-methylbenzylidene
sorbitol, and or aluminum
2,2'-methylene-bis(4,6-di-tert-butylphenyl)phosphate.
54. A package comprising the film of claim 1.
55. A diaper, medical film or packaging film comprising the film of
claim 1.
56. The film of claim 23 wherein the semi-amorphous polymer has a
propylene triad tacticity of 85% or greater.
57. The film of claim 1 wherein the semi-amorphous polymer has a
propylene triad tacticity of 90% or greater.
58. The film of claim 1 wherein the semi-amorphous polymer has an
intermolecular composition distribution of 90% or more by weight of
the polymer isolated as one or two adjacent, soluble fractions with
the balance of the polymer in immediately preceding or succeeding
fractions; and wherein each of these fractions has a weight %
comonomer content with a difference of no greater than 10 wt %
(relative) of the average weight % comonomer of the copolymer.
59. The film of claim 1 wherein the semi-amorphous polymer has an
intermolecular composition distribution of 90% or more by weight of
the polymer isolated as one or two adjacent, soluble fractions with
the balance of the polymer in immediately preceding or succeeding
fractions; and wherein each of these fractions has a weight %
comonomer content with a difference of no greater than 20 wt %
(relative) of the average weight % comonomer of the copolymer.
60. The film of claim 1 wherein the semi-amorphous polymer has an
intermolecular composition distribution of 85% or more by weight of
the polymer isolated as one or two adjacent, soluble fractions with
the balance of the polymer in immediately preceding or succeeding
fractions; and wherein each of these fractions has a weight %
comonomer content with a difference of no greater than 10 wt %
(relative) of the average weight % comonomer of the copolymer.
61. The film of claim 23 wherein the semi-amorphous polymer has an
intermolecular composition distribution of 90% or more by weight of
the polymer isolated as one or two adjacent, soluble fractions with
the balance of the polymer in immediately preceding or succeeding
fractions; and wherein each of these fractions has a weight %
comonomer content with a difference of no greater than 10 wt %
(relative) of the average weight % comonomer of the copolymer.
62. The film of claim 23 wherein the blend has dispersions of
semi-amorphous polymer less than 2 .mu.m in size in a continuous
phase of semi-crystalline polymer.
63. The film of claim 23 wherein the blend has dispersions of
semi-amorphous polymer less than 1 .mu.m in size in a continuous
phase of semi-crystalline polymer.
64. The film of claim 24 wherein the blend has dispersions of
semi-amorphous polymer less than 2 .mu.m in size in a continuous
phase of semi-crystalline polymer.
65. The film of claim 24 wherein the blend has dispersions of
semi-amorphous polymer less than 1 .mu.m in size in a continuous
phase of semi-crystalline polymer.
66. The film of claim 1 wherein the blend has dispersions of
semi-amorphous polymer less than 2 .mu.m in size in a continuous
phase of semi-crystalline polymer.
67. The film of claim 1 wherein the blend has dispersions of
semi-amorphous polymer less than 1 .mu.m in size in a continuous
phase of semi-crystalline polymer.
68. The film of claim 1 wherein the film has a haze of 1% or
less.
69. The film of claim 23 wherein the film has a 45.degree. gloss of
85 units or more.
70. The film of claim 23 wherein the film has a 45.degree. gloss of
89 units or more.
71. The film of claim 1 wherein the film is laminated to a
substrate.
72. The film of claim 71 where the substrate is a non-woven fabric,
paper or a polyolefin.
73. The film of claim 1 wherein a 3.18 mm thick injection molded
pad of the blend has a resistance to stress whitening of Hunter
color .DELTA.L of 15 or less.
74. The film of claim 1 wherein a 3.18 mm thick injection molded
pad of the blend has a resistance to stress whitening of Hunter
color .DELTA.L of 10 or less.
75. The film of claim 1 wherein a 3.18 mm thick injection molded
pad of the blend has a resistance to stress whitening of Hunter
color .DELTA.L of 5 or less.
76. The film of claim 71 where the substrate is selected from the
group consisting of wood, cardboard, metals, metal foils,
metallized surfaces, glass, and glass coatings.
77. The film of claim 71 where the substrate coated with ink, dye,
and or pigment.
Description
PRIORITY CLAIM
[0001] This application claims the benefit of U.S. Ser. No.
60/637,429, filed Dec. 17, 2004 and U.S. Ser. No. 60/655,310 filed
Feb. 22, 2005.
STATEMENT OF RELATED CASES
[0002] This application is related to U.S. Ser. No. 10/716,306,
filed Nov. 18, 2003. This invention is also related to copending
U.S. application Ser. No. 10/402,275 filed Mar. 28, 2003.
FIELD OF THE INVENTION
[0003] This invention relates to heterogeneous polymer blends and
films made therefrom.
BACKGROUND
[0004] Isotactic polypropylene and ethylene/propylene copolymers
are often used in the industry to produce articles such as fibers,
films, molded parts and nonwoven fabrics. Additionally, blending
these polymers with other polymers has also been the subject of
past endeavors.
[0005] For example, U.S. Pat. No. 3,262,992 suggests the addition
of a stereoblock copolymer of ethylene and propylene (having high
crystalline melting points) to isotactic polypropylene leads to
improved mechanical properties of the blend compared to isotactic
polypropylene alone.
[0006] U.S. Pat. Nos. 3,853,969 and 3,378,606, suggest the
formation of in situ blends of isotactic polypropylene and "stereo
block" copolymers of propylene and another olefin of 2 to 12 carbon
atoms, including ethylene and hexene.
[0007] U.S. Pat. No. 3,882,197 suggests blends of stereoregular
propylene/alpha-olefin copolymers, stereoregular propylene, and
ethylene copolymer rubbers.
[0008] U.S. Pat. No. 3,888,949 suggests the synthesis of blend
compositions containing isotactic polypropylene and copolymers of
propylene and an alpha-olefin, containing between 6-20 carbon
atoms, which have improved elongation and tensile strength over
either the copolymer or isotactic polypropylene. Copolymers of
propylene and alpha-olefin are described wherein the alpha-olefin
is hexene, octene or dodecene.
[0009] U.S. Pat. No. 4,461,872, discloses a blend produced in part
by the use of another heterogeneous catalyst system which is
expected to form copolymers which have statistically significant
intramolecular and intermolecular compositional differences.
[0010] Two publications in the Journal of Macromolecules, 1989,
volume 22, pages 3851-3866 describe blends of isotactic
polypropylene and partially atactic polypropylene which purportedly
have desirable tensile elongation properties.
[0011] U.S. Pat. Nos. 5,723,217; 5,726,103; 5,736,465; 5,763,080;
and 6,010,588 suggest several metallocene catalyzed processes to
make polypropylene to produce fibers and fabric. U.S. Pat. No.
5,891,814, discloses a dual metallocene-generated propylene polymer
used to make spunbond fibers. WO 99/19547 discloses a method for
producing spunbonded fibers and fabric derived from a blend of a
propylene homopolymer and a copolymer of polypropylene.
[0012] U.S. Pat. No. 6,342,565 and its equivalent WO 00/070134
disclose, at Table 4, column 24, fibers comprising 80, 90, and 95
weight % of Achieve 3854 and 20, 10 and 5 weight %, respectively of
a propylene/ethylene copolymer having 13.5% ethylene and an ML of
12. These particular blends are not made into films, molded
articles or non-woven materials. The fibers in Table 4 are reported
to be inelastic and are unsuitable in the elastic applications
desired in U.S. Pat. No. 6,342,565.
[0013] U.S. Pat. No. 6,525,157; U.S. Pat. No. 5,504,172; and WO
00/01745 disclose various propylene/ethylene copolymers. US
2003/0130430 discloses blends of two different propylene/ethylene
copolymers. U.S. Pat. No. 6,642,316, WO00/070134, WO 00/01766, U.S.
Pat. No. 6,500,563; U.S. Pat. No. 6,342,565, U.S. Pat. No.
6,500,563 and WO 00/69963 disclose elastic blends of crystalline
polypropylene and propylene/ethylene copolymers. U.S. Pat. No.
6,153,703 discloses blends of semicrystalline copolymers and
propylene ethylene polymers having very high toughness without loss
in modulus. EP 0 629 632 and EP 0 629 631 disclose blends of
polypropylene and ethylene-propylene copolymers having certain
triad tacticities and proportions of inversely inserted propylene
units.
[0014] U.S. Pat. No. 6,635,715 and its equivalents EP 1 003 814 B1
and WO 99/07788 disclose blends of polypropylene and Escorene 4292
with propylene/ethylene copolymers for use as thermoplastic
elastomers.
[0015] EP 0 374 695 A1 discloses visually homogeneous blends of an
ethylene-propylene copolymer and Profax.TM. 6331 by Basell.
[0016] U.S. Pat. No. 6,750,284 discloses thermoplastic membranes
comprising propylene-ethylene copolymers and up to 40 wt %
polypropylene.
[0017] WO 03/040095, WO 03/040201, WO 03/040233, and WO 03/040442
disclose various propylene-ethylene copolymers made with
non-metallocene catalyst compounds. WO 03/040202 discloses films
and sealants made from the propylene-ethylene copolymers made with
non-metallocene catalyst compounds.
[0018] Additional references of interest include WO 94/28042, EP 1
002 814, WO 00/69965, WO 01/48034, WO04035681A2, EP 0 400 333 B1,
EP 0 373 660 B1, WO04060994A1, U.S. Pat. No. 5,453,318, U.S. Pat.
No. 5,298,561, and U.S. Pat. No. 5,331,047.
[0019] This invention is also related to copending U.S. application
Ser. No. 10/402,275 filed Mar. 28, 2003.
[0020] However, none of the above disclose blends having a balanced
set of properties comprising toughness, flexibility and clarity
while still maintaining good crystallizability for convenient
fabrication under polypropylene conditions.
SUMMARY
[0021] This invention relates to a film comprising a heterogeneous
blend comprising:
[0022] 1) from 60 to 99 weight percent of one or more
semi-crystalline polymers (based upon the weight of the
semi-crystalline and semi-amorphous polymers), each
semi-crystalline polymer comprising propylene and from 0 to 5
weight % alpha-olefin comonomer (based upon the weight of the
polymer), said semi-crystalline polymers each having a melting
point between 100 and 170.degree. C. and a melt flow rate of 200
dg/min or less (preferably 50 dg/min or less); and
[0023] 2) from 1 to 40 weight % of one or more semi-amorphous
polymers (based upon the weight of the semi-crystalline and
semi-amorphous polymers), each semi-amorphous polymer comprising
propylene and from 10 to 25 weight % of one or more C2 and/or C4 to
C10 alpha-olefin comonomers, said semi-amorphous polymers each
having:
[0024] a) a heat of fusion of 4 to 70 J/g; and
[0025] b) a melt flow rate of 0.1 to 200 dg/min (preferably 50
dg/min. or less); and
[0026] c) an intermolecular compositional distribution as
determined by thermal fractionation in hexane such that 85% by
weight or more of the polymer is isolated as one or two adjacent,
soluble fractions with the balance of the polymer in immediately
preceding or succeeding fractions; and wherein each of these
fractions has a wt % comonomer content with a difference of no
greater than 20 wt % relative to the average wt % comonomer content
of the copolymer; and
[0027] d) an Mw/Mn of 1.5 to 4, and
[0028] e) a propylene triad tacticity, as measured by .sup.13C NMR,
of 75% or greater,
where the blend has:
[0029] i) a melt flow rate of 0.1 to 50 dg/min (preferably 0.1 to
20 dg/min); and
[0030] ii) less than 5 weight % filler, based upon the weight of
the polymers and the filler,
[0031] iii) a haze of 20% or less as measured on a 1 mm thick
injection molded chip, and
[0032] iv) a permanent set of greater than 65%; and
where the film is 0.1 to 25 mil (2.5 to 635 micron) thick and
has:
[0033] a haze of 10% or less, and
[0034] a 1.degree. Secant tensile modulus of from about 100,000 psi
to about 30,000 psi (690 MPa to 207 MPa), and
[0035] an Elmendorf tear in the machine direction of 45 g/mil or
more (1.77 g/micron or more), and
[0036] an Elmendorf tear in the transverse direction of 45 g/mil or
more (1.77 g/micron or more), and
[0037] a total energy impact of 3 ft.lb or more (4.0 J or more),
and
[0038] a 45 degree gloss of 82 units or more.
[0039] In a preferred embodiment, the blend of the semi-crystalline
and semi-amorphous polymers is a heterogeneous blend, preferably
where the semi-crystalline polymer is the continuous phase and the
semi-amorphous polymer is the discontinuous phase.
[0040] By heterogeneous blend is meant a composition having two or
more morphological phases in the same state. For example a blend of
two polymers where one polymer forms discrete packets dispersed in
a matrix of another polymer is said to be heterogeneous in the
solid state. Also heterogeneous blend is defined to include
co-continuous blends where the blend components are separately
visible, but it is unclear which is the continuous phase and which
is the discontinuous phase. Such morphology is determined using
scanning electron microscopy (SEM) or atomic force microscopy
(AFM), in the event the SEM and AFM provide different data, then
the SEM shall be used. By continuous phase is meant the matrix
phase in a heterogeneous blend. By discontinuous phase is meant the
dispersed phase in a heterogeneous blend.
[0041] By homogeneous blend is meant a composition having
substantially one morphological phase in the same state. For
example a blend of two polymers where one polymer is miscible with
another polymer is said to be homogeneous in the solid state. Such
morphology is determined using scanning electron microscopy. By
miscible is meant that that the blend of two or more polymers
exhibits single-phase behavior for the glass transition
temperature, e.g. the Tg would exist as a single, sharp transition
temperature on the DMTA trace. By contrast, two separate transition
temperatures would be observed for an immiscible blend, typically
corresponding to the temperatures for each of the individual
components of the blend. Thus a polymer blend is miscible when
there is one Tg indicated on the DMTA trace. A miscible blend is
homogeneous, while an immiscible blend is heterogeneous.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] FIG. 1 is a plot of Dynamic Mechanical Thermal Analysis
(DMTA) Testing of a blend similar to Example 3-3. It is a plot of
tan .delta. vs Temperature for a blend composition comprising 33.3
wt % of a semi-amorphous propylene-ethylene copolymer, containing
14.9 wt % ethylene, with 66.7 wt % of a semi-crystalline propylene
homopolymer.
[0043] FIG. 2 is an AFM micrograph of a heterogeneous blend
composition similar to that of Example 3-2. The blend comprises 20
wt % of a semi-amorphous propylene-ethylene copolymer containing
14.5 wt % ethylene, with 80 wt % of a semi-crystalline propylene
homopolymer.
DETAILED DESCRIPTION
[0044] For purposes of this invention and the claims thereto, the
term copolymers means any polymer comprising two or more monomers.
For the purposes of this invention and the claims thereto when a
polymer is referred to as comprising a monomer, the monomer present
in the polymer is the polymerized form of the monomer. Likewise
when catalyst components are described as comprising neutral stable
forms of the components, it is well understood by one of ordinary
skill in the art, that the active form of the component is the form
that reacts with the monomers to produce polymers.
[0045] The new notation numbering scheme for the Periodic Table
Groups is used herein as set out in CHEMICAL AND ENGINEERING NEWS,
63(5), 27 (1985).
[0046] As used herein, the term film applies to fabricated
articles, extruded or otherwise, that have the thickness as the
dominant dimension and where the thickness is uniform and in the
range 0.1 to 25 mil (2.5 to 635 .mu.m). The film can be a monolayer
or part of a combination of layers (multilayer). A monolayer or
multilayer film can be laminated, by extrusion lamination or other
means, to other monolayer or multilayer films. The films can be
prepared by any fabricating mode recognized in the industry, such
as film casting or film blowing.
[0047] As used herein, the term "polypropylene", "propylene
polymer," or "PP" refers to homopolymers, copolymers, terpolymers,
and interpolymers, comprising from 50 to 100 weight % of
propylene.
[0048] As used herein, the term "reactor grade" refers to
polyolefin resin whose molecular weight distribution (MWD), or
polydispersity, has not been substantially altered after
polymerization, except for pelletizing with an antioxidant. The
term particularly includes polyolefins which, after polymerization,
have not been treated, or subjected to treatment, to substantially
reduce viscosity or substantially reduce average molecular
weight.
[0049] As used herein, "metallocene" means one or more compounds
represented by the formula Cp.sub.mMR.sub.nX.sub.q, wherein Cp is a
cyclopentadienyl ring which may be substituted, or derivative
thereof (such as indene or fluorene) which may be substituted; M is
a Group 4, 5, or 6 transition metal, for example titanium,
zirconium, hafnium, vanadium, niobium, tantalum, chromium,
molybdenum and tungsten; R is a substituted or unsubstituted
hydrocarbyl group or hydrocarboxy group having from one to 20
carbon atoms; X may be a halide, a hydride, an alkyl group, an
alkenyl group or an arylalkyl group; and m=1-3; n=0-3; q=0-3; and
the sum of m+n+q is equal to the oxidation state of the transition
metal, further if m is 2 or 3 then any two Cp groups may be bound
to one another through a bridging group T, which is typically a
group 14 atom which may be substituted with one or two hydrocarbyl
groups (a preferred example includes (CH.sub.3).sub.2--Si), if m is
1 then the Cp group may be bound to R via a bridging group T which
is typically a group 14 atom which may be substituted with one or
two hydrocarbyl groups (a preferred example includes
(CH.sub.3).sub.2--Si).
[0050] Abbreviations may be used including: Me=methyl, Et=ethyl,
Bu=butyl, Ph=phenyl, Cp=cyclopentadienyl, Cp*=pentamethyl
cyclopentadienyl, Ind=indenyl, and Flu=fluorene.
[0051] As used herein, "support" or "support composition" refers to
compounds that are particulate and porous that may optionally be
calcined or contacted with a halogen. For example, a fluorided
support composition can be a silicon dioxide support wherein a
portion of the silica hydroxyl groups has been replaced with
fluorine or fluorine containing compounds. Suitable fluorine
containing compounds include, but are not limited to, inorganic
fluorine containing compounds and/or organic fluorine containing
compounds.
[0052] As used herein, "metallocene catalyst system" is the product
of contacting components: (1) one or more metallocenes; (2) one or
more activators; and (3) optionally, one or more support
compositions. Preferred activators include alumoxanes (including
methylalumoxane and modified-methylalumoxane), stoichiometric
activators, ionic activators, non-coordinating anions and the
like.
[0053] As used herein "semi-crystalline polymer" is defined to be
an olefin polymer having a melting point (Tm) of 100.degree. C. or
more (as measured by DSC-second melt, described below). As used
herein a "semi-amorphous polymer" is defined to be an olefin
polymer having a heat of fusion of between 4 and 70 J/g (as
determined by DSC, described below). Melting point (Tm), peak
crystallization temperature (Tc), heat of fusion (Hf) and percent
crystallinity are determined using the following procedure
according to ASTM E 794-85. Differential scanning calorimetric
(DSC) data is obtained using a TA Instruments model 2910 machine or
a Perkin-Elmer DSC 7 machine. In the event that the TA Instruments
2910 machine and the Perkin-Elmer DSC-7 machine produce different
DSC data, the data from the TA Instruments model 2910 shall be
used. Samples weighing approximately 5-10 mg are sealed in aluminum
sample pans. The DSC data is recorded by first cooling the sample
to -50.degree. C. and then gradually heating it to 200.degree. C.
at a rate of 10.degree. C./minute. The sample is kept at
200.degree. C. for 5 minutes before a second cooling-heating cycle
is applied. Both the first and second cycle thermal events are
recorded. Areas under the melting curves are measured and used to
determine the heat of fusion and the degree of crystallinity. The
percent crystallinity (X %) is calculated using the formula, X
%=[area under the curve (Joules/gram)/B (Joules/gram)]*100, where B
is the heat of fusion for the homopolymer of the major monomer
component. These values for B are to be obtained from the Polymer
Handbook, Fourth Edition, published by John Wiley and Sons, New
York 1999. A value of 189 J/g (B) is used as the heat of fusion for
100% crystalline polypropylene. For the semi-crystalline polymers,
having appreciable crystallinity, the melting temperature is
typically measured and reported during the second heating cycle (or
second melt). For the semi-amorphous polymers, having comparatively
low levels of crystallinity, the melting temperature is typically
measured and reported during the first heating cycle. Prior to the
DSC measurement, the sample is aged (typically by holding it at
ambient temperature for a period up to about 5 days) or annealed to
maximize the level of crystallinity.
[0054] As used herein, molecular weight (Mn and Mw) and molecular
weight distribution (MWD or Mw/Mn) are determined by gel permeation
chromatography using polystyrene standards. The GPC data were taken
on a Waters 150 GPC using three Shodex mixed bed AT-80M/S columns.
The solvent used was 1,2,4 trichlorobenzene that contains 300 ppm
of the antioxidant Santonox R. The run conditions were an operating
temperature of 145 C, a nominal flow rate of 1.0 ml/min and a 300
.mu.L injection volume. Solutions for injection were typically 1.0
to 1.5 mg/ml. The columns were calibrated by running a series of
narrow molecular weight polystyrene (PS) standards and recording
their retention volumes. Polypropylene (PP) molecular weight values
were calculated using the "universal calibration" approach and the
following Mark-Houwink coefficients: TABLE-US-00001 k (dL/g) a PS
1.75 .times. 10.sup.-4 0.67 PP 8.33 .times. 10.sup.-5 0.80
A third order fit is used to fit the Log (MW) vs Retention volume
points. The data were taken and analyzed by Waters Millenium
software.
[0055] A clarifying agent is defined to be any agent that causes at
least a 10%, preferably at least 15%, more preferably at least 20%
reduction in haze (as measured on a 1 mm molded chip according to
ASTM D 1003) as compared to the same composition without the
clarifying agent. A nucleating agent is often a clarifying agent. A
nucleating agent is defined to be an additive which forms nuclei in
a polymer melt to promote the growth of crystals (adipic acid,
benzoic acid, or metal salts of these acids, sorbitols, such as
3,4-dimethylbenzylidene sorbitol are examples of nucleating agents,
as are many inorganic fillers).
Blend Components-Semi-Crystalline Polymer
[0056] In a preferred embodiment, the blends of this invention
comprise from 60 to 99 weight percent of one or more
semi-crystalline polymers (based upon the weight of the
semi-crystalline and semi-amorphous polymers), preferably from 60
to 90 weight %, preferably from 60 to 85 weight %, preferably from
60 to 75 weight %, each semi-crystalline polymer comprising
propylene and from 0 to 5 weight % alpha-olefin comonomer (based
upon the weight of the polymer), preferably from 0.1 to 4 weight %,
preferably from 0.25 to 3 weight %. Preferably the alpha olefin
comonomer is a C2 to C10 alpha olefin, preferably selected from the
group consisting of ethylene, butene, pentene, hexene, heptene,
octene, nonene, and decene, preferably ethylene, butene, hexene,
and octene, preferably ethylene. (For purposes of this invention
when a copolymer is described as comprising propylene and one or
more C2 to C10 olefins, or alpha olefins, the C2 to C10 olefins or
alpha olefins do not include C3 e.g. propylene.)
[0057] Preferred semi-crystalline polymers have a melting point
(Tm--second melt as measured by DSC as described above) between 100
and 170.degree. C., preferably between 110 and 170.degree. C.,
preferably between 125 and 170.degree. C.
[0058] Preferred semi-crystalline polymers have a melt flow rate of
from 0.1 to 200 dg/min, preferably 0.25 to 100 dg/min, preferably
from 0.5 to 50 dg/min, preferably 0.5 to 20 dg/min, preferably 1 to
20 dg/min (ASTM 1238-D, 2.16 kg, 230.degree. C.).
[0059] Preferred semi-crystalline polymers have an Elongation at
Break of 700% or less, preferably 300 to 700%, as measured by ASTM
D 638, 2 in/min 50 mm/min on a 0.125 in (3.18 mm) thick injection
molded sample).
[0060] Preferred semi-crystalline polymers have a 1.degree. Secant
Flexural Modulus of from 100,000 psi to 250,000 psi (690 to 1720
MPa), preferably from 150,000 psi to 250,000 psi (1035 to 1720 MPa)
as measured by ASTM D-790A (0.05 in/min 1.3 mm/min).
"High-crystallinity polypropylenes," e.g. those having values above
250,000 psi (1720 MPa) can also be used.
[0061] Any propylene polymer having 0 to 5 weight % comonomer, a
melting point between 100 and 170, and an MFR of 200 dg/min or less
may be used in the practice of this invention. Suitable examples
include polymers produced by Ziegler-Natta catalyst systems,
metallocene systems, and the like. The polymers may be produced by
any means including solution, slurry, gas phase, supercritical or
high pressure. In a particularly preferred embodiment the propylene
polymers useful herein have a molecular weight distribution (Mw/Mn)
of 5 or less preferably between 1.5 and 4 preferably between 1.5
and 3. In another preferred embodiment, preferred propylene
polymers useful herein include those produced by metallocene
catalyst systems. In another embodiment preferred propylene
polymers useful herein include those having a composition
distribution breadth index (CDBI) of 60% or more, preferably 70% or
more, preferably 80% or more, preferably 90% or more. (CDBI is
measured as described in WO 93/03093, with the modification that
any fractions having a weight average molecular weight (Mw) below
25,000 g/mol are disregarded.) Preferred propylene polymers that
can be used in the practice of this invention include those
propylene polymers sold by ExxonMobil Chemical Company under the
tradename ACHIEVE.TM.. Particularly useful grades include
ACHIEVE.TM. 3854, ACHIEVE.TM. 1654E1, ACHIEVE.TM. 3825, ACHIEVE.TM.
1605, available from ExxonMobil Chemical Company in Houston, Tex.
Additional preferred propylene polymers useful in the practice of
this invention include those propylene homopolymers, and random
copolymers available from ExxonMobil Chemical Company under the
grade names: PP1024E4, PP1042, PP1032, PP1044, PP1052, PP1105E1,
PP3155 and PP9852E1, PP9272, PP9513, PP9544, PP9562. In some
instances impact copolymers can be utilized in the practice of this
invention. Several are available from ExxonMobil Chemical Company
(e.g. PP7032 E2).
[0062] In another embodiment preferred semi-crystalline polymers
useful herein have a melting point greater than 110.degree. C.,
preferably greater than 115.degree. C., and most preferably greater
than 130.degree. C. and/or a heat of fusion of greater than 60 J/g,
preferably at least 70 J/g, preferably at least 80 J/g, as
determined by DSC analysis described above.
[0063] The molecular weight of the semi-crystalline polymer can be
between 10,000 to 5,000,000 g/mol, alternatively 50,000 to 500,000
g/mol, preferably with a polydispersity index (PDI--Mw/Mn) between
1.5 to 4, preferably 1.5 to 3.
[0064] Preferred semi-crystalline polymers may be isotactic, highly
isotactic, syndiotactic, or highly syndiotactic. In one embodiment,
the semi-crystalline polymer is an isotactic polypropylene. In
another embodiment, the semi-crystalline polymer is a highly
isotactic polypropylene. As used herein, "isotactic" is defined as
having at least 10% isotactic pentads, preferably having at least
40% isotactic pentads of methyl groups derived from propylene
according to analysis by .sup.13C-NMR. As used herein, "highly
isotactic" is defined as having at least 60% isotactic pentads
according to analysis by .sup.13C-NMR. In a desirable embodiment, a
polypropylene homo- or co-polymer having at least 85% isotacticity
is the semi-crystalline polymer. In another embodiment, the
semi-crystalline polymer has at least 90% isotacticity. As used
herein, "syndiotactic" is defined as having at least 10%
syndiotactic pentads, preferably at least 40%, according to
analysis by .sup.13C-NM. As used herein, "highly syndiotactic" is
defined as having at least 60% syndiotactic pentads according to
analysis by .sup.13C-NMR. In a desirable embodiment, a
polypropylene homo- or co-polymer having at least 85%
syndiotacticity is the semi-crystalline polymer. In another
embodiment, a propylene homo- or co-polymer having at least 90%
syndiotacticity is the semi-crystalline polymer.
Blend Components-Semi-Amorphous Polymer
[0065] In a preferred embodiment, blends of this invention comprise
from 1 to 40 weight percent of one or more semi-amorphous polymers
(based upon the weight of the semi-crystalline and semi-amorphous
polymers), preferably from greater than 10 to 40 weight %,
preferably from 15 to 40 weight %, preferably from 25 to 40 weight
%. In some embodiments, the semi-amorphous polymers comprise
propylene and from 10 to 25 weight % of one or more C2 to C10
alpha-olefin comonomers, preferably from 10 to 20 weight %,
preferably from 12 to 20 weight %, based upon the weight of the
copolymer. Preferably the alpha olefin comonomer is a C2 to C10
alpha olefin selected from the group consisting of ethylene,
butene, pentene, hexene, heptene, octene, nonene, and decene,
preferably ethylene, butene, hexene, and octene, preferably
ethylene.
[0066] The ethylene content of the semi-amorphous polymers can be
measured as follows. A thin homogeneous film is pressed at a
temperature of about 150.degree. C. or greater, then mounted on a
Perkin Elmer PE 1760 infrared spectrophotometer. A full spectrum of
the sample from 600 cm.sup.-1 to 4000 cm.sup.-1 is recorded and the
monomer weight percent of ethylene can be calculated according to
the following equation: Ethylene wt %=82.585-111.987X+30.045
X.sup.2, wherein X is the ratio of the peak height at 1155
cm.sup.-1 and peak height at either 722 cm.sup.-1 or 732 cm.sup.-1,
whichever is higher.
[0067] Preferred semi-amorphous polymers having from 10 to 25
weight % comonomers useful in this invention preferably have a
percent crystallinity of 2.5 to 25%, preferably from 5 to 23%,
preferably from 5 to 20%. Percent crystallinity is determined
according to the DSC procedure described above.
[0068] Preferred semi-amorphous polymers useful in this invention
preferably have a melt flow rate of 0.1 to 200 dg/min, preferably
0.1 to 100 dg/min, preferably 0.5 to 50, preferably 1 to 25,
preferably 1 to 20 dg/min (as measured by ASTM 1238, 2.16 kg and
230.degree. C.).
[0069] Preferred semi-amorphous polymers useful in this invention
preferably have a DSC melting point (Tm) of 105.degree. C. or less,
preferably 90.degree. C. or less, preferably between 25 and
90.degree. C., preferably between 30 and 80.degree. C., preferably
between 35 and 75.degree. C., as measured by the DSC procedure
described above.
[0070] Preferred semi-amorphous polymers useful in this invention
preferably have an intermolecular composition distribution of 75%
or more, preferably 80% or more, preferably 85% or more, preferably
90% or more by weight of the polymer isolated as one or two
adjacent, soluble fractions with the balance of the polymer in
immediately preceding or succeeding fractions; and wherein each of
these fractions has a weight % comonomer content with a difference
of no greater than 20 wt % (relative), preferably 10% (relative),
of the average weight % comonomer of the copolymer. The fractions
are obtained at temperature increases of approximately 8 C between
stages. The intermolecular composition distribution of the
copolymer is determined by thermal fractionation in hexane as
follows: about 30 grams of the semi-amorphous polymer is cut into
small cubes of about 1/8 inch (0.32 cm) on the side and is then
introduced into a thick walled glass bottle closed with screw cap
along with 50 mg of Irganox1076, an antioxidant commercially
available from Ciba-Geigy Corporation. Then, 425 ml of hexane (a
principal mixture of normal and iso isomers) is added to the
contents of the bottle and the sealed bottle is maintained at about
23.degree. C. for 24 hours. At the end of this period, the solution
is decanted and the residue is treated with additional hexane for
an additional 24 hours at 23.degree. C. At the end of this period,
the two hexane solutions are combined and evaporated to yield a
residue of the polymer soluble at 23.degree. C. To the residue is
added sufficient hexane to bring the volume to 425 ml and the
bottle is maintained at about 31.degree. C. for 24 hours in a
covered circulating water bath. The soluble polymer is decanted and
the additional amount of hexane is added for another 24 hours at
about 31.degree. C. prior to decanting. In this manner, fractions
of the semi-amorphous polymer soluble at 40.degree. C., 48.degree.
C., 55.degree. C., and 62.degree. C. are obtained at temperature
increases of approximately 8.degree. C. between stages. The soluble
polymers are dried, weighed and analyzed for composition, as wt %
ethylene content. To produce a copolymer having the desired narrow
composition, it is beneficial if (1) a single sited metallocene
catalyst is used which allows only a single statistical mode of
addition of the first and second monomer sequences and (2) the
copolymer is well-mixed in a continuous flow stirred tank
polymerization reactor which allows only a single polymerization
environment for substantially all of the polymer chains of the
copolymer.
[0071] Preferred semi-amorphous polymers useful in this invention
preferably have a molecular weight distribution (Mw/Mn) of Mw/Mn of
less than 5, preferably between 1.5 and 4, preferably between 1.5
and 3.
[0072] In another embodiment polymers that are useful in this
invention as semi-amorphous polymers include homopolymers and
random copolymers of propylene having a heat of fusion as
determined by Differential Scanning Calorimetry (DSC) of less than
70 J/g, an MFR of 50 dg/min or less, and contain stereoregular
propylene crystallinity preferably isotactic stereoregular
propylene crystallinity. In another embodiment the polymer is a
random copolymer of propylene and at least one comonomer selected
from ethylene, C.sub.4-C.sub.12 .alpha.-olefins, and combinations
thereof. Preferably the random copolymers of propylene comprises
from 10 wt % to 25 wt % polymerized ethylene units, based on the
total weight of the polymer; has a narrow intermolecular
composition distribution (e.g. 75% or more by thermal
fractionation); has a melting point (Tm) of from 25.degree. C. to
120.degree. C., or from 35.degree. C. to 80.degree. C.; has a heat
of fusion within the range having an upper limit of 70 J/g or 25
J/g and a lower limit of 1 J/g or 3 J/g; has a molecular weight
distribution Mw/Mn of from 1.8 to 4.5; and has a melt flow rate of
less than 40 dg/min, or less than 20 dg/min (as measured at
230.degree. C., and 2.16 kg, ASTM 1238).
[0073] A particularly preferred polymer useful in the present
invention as a semi-amorphous polymer is a polymer with a moderate
level of crystallinity due to stereoregular propylene sequences.
The polymer can be: (A) a propylene homopolymer in which the
crystallinity is disrupted in some manner such as by
regio-inversions and stereo defects; (B) a random propylene
copolymer in which the propylene crystallinity is disrupted at
least in part by comonomers; or (C) a combination of (A) and
(B).
[0074] In one embodiment, the useful polymers described above
further include a non-conjugated diene monomer to aid in later
chemical modification of the blend composition (such as
crosslinking). The amount of diene present in the polymer is
preferably less than 10% by weight, and more preferably less than
5% by weight. The diene may be any non-conjugated diene which is
commonly used in ethylene propylene copolymers including, but not
limited to, ethylidene norbornene, vinyl norbornene, and
dicyclopentadiene.
[0075] In one embodiment, the semi-amorphous polymer is a random
propylene copolymer having a narrow composition distribution. In
another embodiment, the semi-amorphous polymer is a random
propylene copolymer having a narrow composition distribution and a
melting point of from 25.degree. C. to 120.degree. C., preferably
25.degree. C. to 90.degree. C. The copolymer is described as random
because for a polymer comprising propylene, comonomer, and
optionally diene, the number and distribution of comonomer residues
is consistent with the random statistical polymerization of the
monomers. In stereoblock structures, the number of block monomer
residues of any one kind adjacent to one another is greater than
predicted from a statistical distribution in random copolymers with
a similar composition. Historical ethylene-propylene copolymers
with stereoblock structure have a distribution of ethylene residues
consistent with these blocky structures rather than a random
statistical distribution of the monomer residues in the polymer.
The intermolecular composition distribution (i.e., randomness) of
the copolymer may be determined by .sup.13C NMR, which locates the
comonomer residues in relation to the neighboring propylene
residues. The intermolecular composition distribution of the
copolymer is determined by thermal fractionation in hexane as
previously described.
[0076] In another embodiment, semi-amorphous polymers useful herein
have a heat of fusion of 70 J/g or less, as determined by DSC
described above, preferably from 1 to 65 J/g, preferably from 2 to
50 J/g, preferably from 4 to 45 J/g.
[0077] In another embodiment, semi-amorphous polymers useful herein
have a weight average molecular weight of from 20,000 to 1,000,000,
preferably from 50,000 to 500,000, preferably from 125,000 to
400,000 g/mol.
[0078] Preferred semi-amorphous polymers used in embodiments of the
present invention have a propylene tacticity index (m/r) ranging
from a lower limit of 4 or 6 to an upper limit of about 8, 10, or
12. The propylene tacticity index, expressed herein as "m/r", is
determined by .sup.13C nuclear magnetic resonance (NMR). The
propylene tacticity index m/r is calculated as defined in H. N.
Cheng, Macromolecules, 17, 1950 (1984). The designation "m" or "r"
describes the stereochemistry of pairs of contiguous propylene
groups, "m" referring to meso and "r" to racemic. An m/r ratio of 0
to less than 1.0 generally describes a syndiotactic polymer, and an
m/r ratio of 1.0 an atactic material, and an m/r ratio of greater
than 1.0 an isotactic material. An isotactic material theoretically
may have a ratio approaching infinity, and many by-product atactic
polymers have sufficient isotactic content to result in ratios of
greater than 50.
[0079] In a preferred embodiment, the preferred semi-amorphous
polymers have isotactic stereoregular propylene crystallinity. The
term "stereoregular" as used herein means that the predominant
number, i.e. greater than 80%, of the propylene residues in the
polypropylene exclusive of any other monomer such as ethylene, has
the same 1,2 insertion and the stereochemical orientation of the
pendant methyl groups is the same, either meso or racemic.
[0080] Preferred semi-amorphous polymers useful in this invention
have a triad tacticity of three propylene units, as measured by
.sup.13C NMR, of 75% or greater, 80% or greater, 82% or greater,
85% or greater, or 90% or greater. The triad tacticity of a polymer
is the relative tacticity of a sequence of three adjacent propylene
units, a chain consisting of head to tail bonds, expressed as a
binary combination of m and r sequences. It is usually expressed
for semi-amorphous copolymers of the present invention as the ratio
of the number of units of the specified tacticity to all of the
propylene triads in the copolymer. The triad tacticity (mm
fraction) of a propylene copolymer can be determined from a
.sup.13C NMR spectrum of the propylene copolymer and the following
formula: m .times. .times. m .times. .times. Fraction = PPP
.function. ( m .times. .times. m ) PPP .function. ( m .times.
.times. m ) + PPP .function. ( m .times. .times. r ) + PPP
.function. ( r .times. .times. r ) ##EQU1## where PPP(mm), PPP(mr)
and PPP(rr) denote peak areas derived from the methyl groups of the
second units in the following three propylene unit chains
consisting of head-to-tail bonds: ##STR1## The .sup.13C NMR
spectrum of the propylene copolymer is measured as described in
U.S. Pat. No. 5,504,172. The spectrum relating to the methyl carbon
region (19-23 parts per million (ppm)) can be divided into a first
region (21.2-21.9 ppm), a second region (20.3-21.0 ppm) and a third
region (19.5-20.3 ppm). Each peak in the spectrum was assigned with
reference to an article in the journal Polymer, Volume 30 (1989),
page 1350. In the first region, the methyl group of the second unit
in the three propylene unit chain represented by PPP (mm)
resonates. In the second region, the methyl group of the second
unit in the three propylene unit chain represented by PPP (mr)
resonates, and the methyl group (PPE-methyl group) of a propylene
unit whose adjacent units are a propylene unit and an ethylene unit
resonates (in the vicinity of 20.7 ppm). In the third region, the
methyl group of the second unit in the three propylene unit chain
represented by PPP (rr) resonates, and the methyl group (EPE-methyl
group) of a propylene unit whose adjacent units are ethylene units
resonates (in the vicinity of 19.8 ppm). The calculation of the
triad tacticity is outlined in the techniques shown in U.S. Pat.
No. 5,504,172. Subtraction of the peak areas for the error in
propylene insertions (both 2,1 and 1,3) from peak areas from the
total peak areas of the second region and the third region, the
peak areas based on the 3 propylene units-chains (PPP(mr) and
PPP(rr)) consisting of head-to-tail bonds can be obtained. Thus,
the peak areas of PPP(mm), PPP(mr) and PPP(rr) can be evaluated,
and hence the triad tacticity of the propylene unit chain
consisting of head-to-tail bonds can be determined.
[0081] In another embodiment polymers that are useful in this
invention as semi-amorphous polymers include homopolymers and
random copolymers of propylene having a heat of fusion as
determined by Differential Scanning Calorimetry (DSC) of less than
70 J/g, an MFR of 50 dg/min or less, and contain stereoregular
propylene crystallinity preferably isotactic stereoregular
propylene crystallinity. In another embodiment the polymer is a
random copolymer of propylene and at least one comonomer selected
from ethylene, C.sub.4-C.sub.12 .alpha.-olefins, and combinations
thereof. Preferably the random copolymers of propylene comprises
from 10 wt % to 25 wt % polymerized ethylene units, based on the
total weight of the polymer; has a narrow intermolecular
composition distribution (e.g. 75% or more); has a melting point
(Tm) of from 25.degree. C. to 120.degree. C., or from 35.degree. C.
to 80.degree. C.; has a heat of fusion within the range having an
upper limit of 70 J/g or 25 J/g and a lower limit of 1 J/g or 3
J/g; has a molecular weight distribution Mw/Mn of from 1.8 to 4.5;
and has a melt flow rate of less than 40 dg/min, or less than 20
dg/min (as measured at 230.degree. C., and 2.16 kg, ASTM
D-1238).
[0082] Preferred polymers useful as semi-amorphous copolymers in
this invention are also those polymers described in detail as the
"Second Polymer Component (SPC)" in WO 00/69963, WO 00/01766, WO
99/07788, WO 02/083753, and described in further detail as the
"Propylene Olefin Copolymer" in WO 00/01745, all of which are fully
incorporated by reference herein.
[0083] Preferred semi-amorphous copolymers may be produced in a
solution process using a metallocene catalyst as follows. In a
preferred embodiment, a continuous solution polymerization process
is used to produce copolymers of propylene and from 10 to 25 weight
% ethylene preferably utilizing a metallocene catalyst, namely,
1,1'-bis(4-triethylsilylphenyl)methylene-(cyclopentadienyl)(2,7-di-tertia-
ry-butyl-9-fluorenyl)hafnium dimethyl with
dimethylaniliniumtetrakis-(pentafluorophenyl) borate as an
activator. An organoaluminum compound, namely, tri-n-octylaluminum,
may be added as a scavenger to the monomer feedstreams prior to
introduction into the polymerization process. For preferred
polymers, dimethylsilylbis(indenyl)hafnium dimethyl is used in
combination with
dimethylaniliniumtetrakis(pentafluorophenyl)borate. In other
embodiments, dimethylsilyl bis(2-methyl-5-phenylindenyl) zirconium
di alkyl (such as methyl) and or dimethylsilyl
bis(2-methylindenyl)zirconium di alkyl (such as methyl) is used
with an activator
(dimethylaniliniumtetrakis(pentafluorophenyl)borate and or triaryl
carbenium(pentafluorophenyl)borate). Preferably the solution
polymerization is conducted in a single, or optionally in two,
continuous stirred tank reactors connected in series with hexane
used as the solvent. In addition, toluene may be added to increase
the solubility of the co-catalyst. The feed is transferred to the
first reactor at a reaction temperature between about 50.degree. C.
to about 220.degree. C. Hydrogen gas may also be added to the
reactors as a further molecular weight regulator. If desired,
polymer product is then transferred to a second reactor, which is
operated at a temperature between about 50.degree. C. to
200.degree. C. Additional monomers, solvent, metallocene catalyst,
and activators can be fed to the second reactor.
[0084] Preferred semi-amorphous polymers may also be produced by
the continuous solution polymerization process described in WO
02/34795, advantageously in a single reactor and separated by
liquid phase separation from the alkane solvent. Preferred
semi-amorphous polymers may also be produced by the polymerization
process described at page 6 lines 24-57 of EP 1 003 814 B1.
[0085] Further detailed instructions on how to make such preferred
semi-amorphous polymers can be found in WO 02/083754.
[0086] Preferred semi-amorphous polymers useful herein are made
using a metallocene catalyst system.
[0087] Preferred semi-amorphous polymers include VM.TM.1000,
VM.TM.2000, and VM.TM.3000 available from ExxonMobil Chemical
Company in Houston, Tex.
Blend Properties
[0088] In a preferred embodiment, the blend described herein is
heterogeneous, characterized by a fine dispersion of the
discontinuous phase uniformly distributed in the matrix. The
dimensions of the discontinuous phase in an article, depend on the
product composition and on the fabricating mode used to prepare the
article. For example, injection molding will introduce orientation
along the flow direction causing some elongation of the dispersed
phase particles. This can be observed in FIG. 2, which is an AFM
micrograph of a heterogeneous blend composition comprising 20 wt %
of a semi-amorphous propylene-ethylene copolymer, containing 14.5
wt % ethylene, with 80 wt % of a propylene homopolymer. In the
figure, the flow direction is vertical. The dispersed phase
(semi-amorphous propylene-ethylene copolymer) shows up dark in the
micrograph, while the matrix (polypropylene) shows up light.
Despite the orientation effect along the flow direction, FIG. 2
shows dispersed phase particles with the large dimension generally
no greater than 1 .mu.m (note that the field of view in FIG. 2 is 5
.mu.m.times.5 .mu.m). It is theorized that this feature of a fine
dispersion contributes to achieving good clarity.
[0089] In a preferred embodiment, the blend of the semi-crystalline
and semi-amorphous polymers is a heterogeneous blend, preferably
where the semi-crystalline polymer is the continuous phase, and the
semi-amorphous polymer is the discontinuous phase.
[0090] In another embodiment, depending on the composition, the
blend could be heterogeneous with two phases, but the two phases
could be co-continuous. In this case, it is not possible to
definitively attribute one component to the matrix and the other to
the dispersed phase, rather, both components share the matrix.
[0091] In another preferred embodiment the blend the film is
prepared from is heterogeneous and has a haze below 20% (1 mm thick
injection molded chip sample) and the film has an Elmendorf tear in
the MD and TD of 45 g/mil or more and a total energy impact of 3
ft.lb or more (4.0 J or more).
[0092] The blends of the present invention can be prepared by any
procedure that causes the intimate admixture of the components.
This includes reactor blends, where the semi-crystalline
polypropylene component is polymerized in one reactor (or one stage
of one reactor) and the polymerized product is transferred to a
different reactor or different stage of the same reactor, where
polymerization of the semi-amorphous polymer occurs. The final
blend product comprises an intimate mix of the two polymer
components. Alternately, the blends can be prepared by post-reactor
mixing of the semi-crystalline and semi-amorphous polymer
components. For example, they may be blended in a tumbler, static
mixer, batch mixer, extruder, or a combination thereof. The mixing
step may take place as part of a processing method used to
fabricate articles, such as in the extruder on an injection
molding, machining or fiber line. Likewise, the components can be
combined by melt pressing the components together on a Carver press
to a thickness of 0.5 millimeter (20 mils) and a temperature of
180.degree. C., rolling up the resulting slab, folding the ends
together, and repeating the pressing, rolling, and folding
operation 10 times. Internal mixers are particularly useful for
solution or melt blending. Blending at a temperature of 180.degree.
C. to 240.degree. C. in a Brabender Plastograph for 1 to 20 minutes
has been found satisfactory. Still another method that may be used
for admixing the components involves blending the polymers in a
Banbury internal mixer above the flux temperature of all of the
components, e.g., 180.degree. C. for 5 minutes. A complete mixture
of the polymeric components is indicated by the uniformity of the
morphology of the dispersion of the semicrystalline polymer(s) and
the semi-amorphous polymer(s). Continuous mixing may also be used.
These processes are well known in the art and include single and
twin screw mixing extruders, static mixers for mixing molten
polymer streams of low viscosity, impingement mixers, as well as
other machines and processes, designed to disperse the
semi-crystalline polymer component and the semi-amorphous polymer
component in intimate contact.
[0093] In a preferred embodiment, blend has dispersions of
semi-amorphous polymer less than 4 .mu.m in size in a continuous
phase of semi-crystalline polymer, preferably the dispersions (also
called dispersed particles) are 3 .mu.m or less, preferably 2 .mu.m
or less, preferably 1 .mu.m or less. (By dispersions less than 4
.mu.m in size is meant that the average dispersion size is 4 .mu.m
or less).
[0094] The blends of the present invention preferably have a
permanent tension set of 65% or more, preferably 85% or more,
preferably 100% or more, preferably 125% or more, preferably 150%
or more.
[0095] Permanent tension set is measured according to the following
procedure. Hysteresis testing is done on molded samples having the
required dumbbell geometry (ASTM designation type I bars for
polypropylene), using the following test procedure. The deformable
zone (2.54 cm long section) of the sample is stretched to 200% of
its original length at a deformation rate of 20 in/min (51 cm/min)
in an Instron (The Instron Corporation, Canton, Mass.) testing
machine. The sample is then allowed to relax while the machine
retracts and comes back to the point where the stress is zero. The
machine resets the new zero elongation point at this position. With
the specimen still within the grips, the second cycle is then
initiated for another 200% extension. Again, the machine is allowed
to come back to the point where the stress is zero on the
retraction cycle. The set for each cycle is determined with
reference to their respective zero elongation points. Two specimens
are tested for each sample. The average of the set values over the
two cycles is taken as the permanent tension set.
[0096] The blends of the present invention preferably have a haze
of 20% or less, preferably 15% or less, preferably 12% or less,
preferably 10% or less, as measured by ASTM D 1003 on a 1 mm thick
injection molded haze chip sample provided that the blend in
question is combined with 2500 ppm of bis(3,4
dimethylbenzylidene)sorbitol (also called DMDBS and is available as
(Millad 3988 from Milliken Chemicals) prior to being molded into
the 1 mm chip. While the inventive blends are combined with a
clarifying agent for haze testing of the blend, the final films of
the invention may or may not contain clarifying agent. Film haze is
also measured according to ASTM-D 1003.
[0097] The blends of the present invention contain less than 5 wt %
filler, based on the weight of the polymers and the filler.
[0098] In another embodiment, the blends of the present invention
preferably have a melt flow rate (ASTM D-1238 Condition L;
230.degree. C., 2.16 kg) of 0.1 to 200 dg/min, preferably 0.1 to
100 dg/min, preferably 0.5 to 50 dg/min, preferably 0.5 to 30
dg/min, preferably 1.0 to 25 dg/min.
[0099] In another embodiment, the heterogeneous blends of the
present invention show surprisingly good blush resistance (ie. very
low to no stress-whitening). Stress-whitening, or blushing, in
heterogeneous propylene copolymers is caused by the formation of
voids or crazes during the deforming of a specimen, upon
application of stress. Light is diffracted from the crazes and
voids giving rise to the whitening, which presents an undesirable
appearance. The detailed test procedure to quantify the amount of
stress whitening is discussed below. In essence, a molded part is
impacted using a falling-weight impact tester. The impact of the
tup weight induces stress-whitening, if the sample is susceptible.
Color readings (Hunter color "L"; a measure of the black-white
spectrum) are taken on the molded specimen, at the impact area and
outside the impact area. The degree of stress whitening is judged
as the difference between the Hunter "L" color readings of the two
measurements. In other words .DELTA.L is determined, where .DELTA.L
is defined as Hunter "L" value of impact area minus Hunter "L"
value of non-impact area. In one embodiment, the heterogeneous
blends of the present invention show .DELTA.L less than 25,
preferably less than 20, preferably less than 15, preferably less
than 10, preferably less than 5. In another embodiment, the blends
of the present invention show negative .DELTA.L values (ie. Hunter
"L" value for impact area is less than Hunter "L" value for
non-impact area).
[0100] Stress Whitening Test Procedure: An injection molded ASTM
specimen (e.g. Gardner disk), 125 mil (3.18 mm) thick, is impacted
with a 4 lb (1.82 kg) weight from a height of 5 in (ie. 20 in.lb or
2.26 J), using a falling-weight impact tester. The impact of the
tup weight is utilized to induce stress-whitening in the specimen,
if it is susceptible. After impact, the specimen is aged for 24
hour. After aging, color readings are taken on the specimen at the
impact area and outside the impact area, using a Hunter Color Quest
XE calorimeter. The colorimeter is set up for Hunter lab readings
using illuminant D65/10.degree.. D65 or D.sub.65 is the most
commonly used daylight illuminant, representing noon daylight. 10
refers to the angular coverage (i.e. 10.degree.) by the illuminant.
A reading is taken with the disk's impact area centered over the
reflectance port. A reading is also taken outside the impact area.
The degree of stress-whitening is judged as the difference between
the "L" readings of the two measurements. Hunter "L" is a measure
of the black-white color spectrum (L=100 white, L=0 black). If a
sample displays stress-whitening, the "L" value on the impact area
will be higher (whiter) than the "L" value on the non-impact area
and a positive .DELTA.L ("L" on impact area--"L" on non-impact
area) will be obtained. The values for .DELTA.L provide a means for
comparing the relative susceptibility to stress-whitening among a
set of samples. Three specimens per sample are generally tested and
the "L" values averaged.
[0101] In certain embodiments, the blends of the present invention
may also comprise a third polymer component. The third polymer
component may be added to the semi-crystalline polymer, the
semi-amorphous polymer or the blend by methods well known in the
art. In these embodiments, the third polymer component (TPC)
comprises low density polyethylene (density 0.915 to less than
0.935 g/cm.sup.3), linear low density polyethylene, ultra low
density polyethylene (density 0.85 to less than 0.90 g/cm.sup.3),
very low density polyethylene (density 0.90 to less than 0.915
g/cm.sup.3), medium density polyethylene (density 0.935 to less
than 0.945 g/cm.sup.3), high density polyethylene (density 0.945 to
0.98 g/cm.sup.3), or combinations thereof. For example,
polyethylene produced using a metallocene catalyst system (mPEs),
i.e., ethylene homopolymers or copolymers may be employed. In a
particular example, mPE homopolymers and copolymer are those
produced using mono- or bis-cyclopentadienyl transition metal
catalysts in combination with an activator of alumoxane and/or a
non-coordinating anion in solution, slurry, high pressure or gas
phase. The catalyst and activator may be supported or unsupported
and the cyclopentadienyl rings may be substituted or unsubstituted.
Illustrative but not exclusive commercially products are available
from ExxonMobil Chemical Company, Houston, Tex., under the
tradenames EXCEED.TM. and EXAC.TM. among others well known in the
industry. In another embodiment, the third component is a propylene
polymer or copolymer, an EP/EPDM copolymer rubber, EVA, or other
type of polyolefin.
[0102] The blends of this invention may also comprise additives and
other ingredients. For example the blends of this invention may
comprise slip agents, preferably present at 50 ppm to 10 weight %,
preferably 50 to 5000 ppm. Preferably the slip additives are
present at 0.001 to 1 wt % (10 to 10,000 ppm), more preferably 0.01
to 0.5 wt % (100 to 5000 ppm), more preferably 0.1 to 0.3 wt %
(1000 to 3000 ppm), based upon the weight of the composition.
Desirable slip additives include but are not limited to saturated
fatty acid amides (such as palmitamide, stearamide, arachidamide,
behenamide, stearyl stearamide, palmityl pamitamide, and stearyl
arachidamide); saturated ethylene-bis-amides (such as
stearamido-ethyl-stearamide, stearamido-ethyl-palmitamide, and
palmitamido-ethyl-stearamide); unsaturated fatty acid amides (such
as oleamide, erucamide, and linoleamide); unsaturated
ethylene-bis-amides (such as ethylene-bis-stearamide,
ethylene-bis-oleamide, stearyl-erucamide,
erucamido-ethyl-erucamide, oleamido-ethyl-oleamide,
erucamido-ethyl-oleamide, oleamido-ethy-lerucamide,
stearamido-ethyl-erucamide, erucamido-ethyl-palmitamide, and
palmitamido-ethyl-oleamide); glycols; polyether polyols (such as
Carbowax); acids of aliphatic hydrocarbons (such as adipic acid and
sebacic acid); esters of aromatic or aliphatic hydrocarbons (such
as glycerol monostearate and pentaerythritol monooleate);
styrene-alpha-methyl styrene; fluoro-containing polymers (such as
polytetrafluoroethylene, fluorine oils, and fluorine waxes);
silicon compounds (such as silanes and silicone polymers, including
silicone oils, modified silicones and cured silicones); sodium
alkylsulfates, alkyl phosphoric acid esters; and mixtures thereof.
Preferred slip additives are unsaturated fatty acid amides, which
are available from Crompton (Kekamide.TM. grades) and Croda
Universal (Crodamide.TM. grades). Particularly preferred are the
erucamide and oleamide versions of unsaturated fatty acid amides.
Preferred slip agents include amides having the chemical structure
CH.sub.3(CH.sub.2).sub.7CH.dbd.CH(CH.sub.2).sub.xCONH.sub.2 where x
is 5 to 15. Particularly preferred amides include: 1) Erucamide
CH.sub.3(CH.sub.2).sub.7CH.dbd.CH(CH.sub.2).sub.11CONH.sub.2 which
may also be referred to as cis-13-docosenoamide (Erucamide is
commercially available from Akzo Nobel Amides Co. Ltd. under the
trade name ARMOSLIP E); 2) Oleylamide
CH.sub.3(CH.sub.2).sub.7CH.dbd.CH(CH.sub.2).sub.8CONH.sub.2; and 3)
Oleamide which may also be preferred to as
N-9-octadecenyl-hexadecanamide)
CH.sub.3(CH.sub.2).sub.7CH.dbd.CH(CH.sub.2).sub.7CONH.sub.2. In
another embodiment, stearamide is also useful in this invention.
Other preferred slip additives include those described in WO
2004/005601A1.
[0103] The blends of this invention may also comprise clarifying
agent. Preferably the clarifying agent is present at from 10 ppm to
10 weight %, more preferably 25 ppm to 5 weight %, preferably 50
ppm to 4000 ppm, based on total polymer in the blend composition.
Preferred clarifying agents include organophosphates, phosphate
esters, sodium benzoate, talc, sorbitol, adipic acid, benzoic acid,
(or metal salts of these acids), inorganic fillers, and the like.
Preferred clarifying agents preferably comprise 50 to 4000 ppm of
sorbitol-based agents, aluminum salt based agents, sodium salt
based agents. Preferred clarifying agents include nucleating agents
such as: Hyperform (e.g. HPN-68) and Millad additives (e.g. Millad
3988-3,4-dimethylbenzylidene sorbitol, dibenzylidene sorbitol) from
Milliken Chemicals, Spartanburg, S.C., organophosphates like NA-11
and NA-21 from Amfine Chemicals, Allendale, N.J. Also, other
nucleating agents may also be employed such as Ziegler-Natta olefin
product or other highly crystalline polymers. Particularly
preferred clarifying agents include disodium[2.2.1]heptane
bicyclodicarboxylate, bis(3,4 dimethylbenzylidene)sorbitol, sodium
2,2'-methylene-bis(4,6-di-tert-butylphenyl) phosphate, (p-chloro,
p'methyl)dibenzylidene sorbitol, bis(p-ethylbenzylidene)sorbitol,
1,2,3,4-dibenzylidene sorbitol, 1,2,3,4-di-para-methylbenzylidene
sorbitol, and or aluminum
2,2'-methylene-bis(4,6-di-tert-butylphenyl)phosphate.
[0104] Further, a variety of additives may be incorporated into the
embodiments described above used to make the blends and films for
various purposes. Such additives include, for example, stabilizers,
antioxidants, fillers, colorants, and antiblock agents. Primary and
secondary antioxidants include, for example, hindered phenols,
hindered amines, and phosphites. Nucleating agents include, for
example, sodium benzoate and talc. Also, other nucleating agents
may also be employed such as Ziegler-Natta olefin product or other
highly crystalline polymer. Antiblock agents include amorphous
silicas, talc, zin stearate among others. a Additives such as
dispersing agents, for example, Acrowax C, can also be included.
Catalyst deactivators are also commonly used, for example, calcium
stearate, hydrotalcite, and calcium oxide, and/or other acid
neutralizers known in the art.
[0105] Other additives include, for example, fire/flame retardants,
plasticizers, vulcanizing or curative agents, vulcanizing or
curative accelerators, cure retarders, processing aids, tackifying
resins, and the like. The aforementioned additives may also include
fillers and/or reinforcing materials, either added independently or
incorporated into an additive. Examples include carbon black, clay,
talc, calcium carbonate, mica, silica, silicate, combinations
thereof, and the like. Other additives which may be employed to
enhance properties include lubricants and UV stabilizers. The lists
described herein are not intended to be inclusive of all types of
additives which may be employed with the present invention. Upon
reading this disclosure, those of skilled in the art will
appreciate other additives may be employed to enhance properties.
As is understood by the skilled in the art, the blends of the
present invention may be modified to ad just the characteristics of
the blends as desired.
[0106] Process oils can also be optimally added to the embodiments
described above. The blend may include process oil in the range of
from 1 to 50, alternatively in the range of from 2 to 20 parts by
weight of process oil per hundred parts of total polymer
components. The addition of process oil in moderate amounts lowers
the viscosity and stiffness of the blend while improving the
properties of the blend at temperatures near and below 0.degree. C.
It is believed that these benefits arise by the lowering of the Tg
of the blend. Additional benefits of adding process oil to the
blend include improved processibilty and a better balance of
elastic and tensile strength. The process oils typically consist of
(a) hydrocarbons consisting essentially of carbon and hydrogen with
traces of hetero atoms such as oxygen or (b) essentially of carbon,
hydrogen and at least one hetero atom such as dioctyl phthalate,
ethers and polyethers. Preferred process oils have a high boiling
point to be substantially involatile at 200.degree. C. Such process
oils are commonly available either as neat solids or liquids or as
physically absorbed mixtures of these materials on an inert support
(e.g. clays, silica) to form a free flowing powder. Other useful
process oils include a mixture of a large number of chemical
compounds which may consist of linear, acyclic but branched, cyclic
and aromatic carbonaceous structures. Another family of useful
process oils are certain low to medium molecular weight (Molecular
weight (M.sub.n)<10,000) organic esters and alkyl ether esters.
Examples of process oils are Sunpar.TM. 150 and 220 from The Sun
Manufacturing Company of Marcus Hook, Pa., USA and Hyprene.TM. V750
and Hyprene.TM. V1200 from Ergon, in Jackson, Miss. and IRM 903
from Calumet Lubricants Company in Princeton, La. It is also
anticipated that combinations of process oils each of which is
described above may be used in the practice of the invention. In
certain embodiments, it is important that in the selection the
process oil be compatible or miscible with the blend composition in
the melt to form a homogenous one phase blend, although two phase
blends and multi-phase blends are also contemplated. The addition
of the process oils to the blend or blend polymer components maybe
made by any of the conventional means known to the art.
[0107] The addition of certain process oils to lower the glass
transition temperature of the blends of isotactic polypropylene and
ethylene propylene diene rubber has been described in the art by
Ellul in U.S. Pat. Nos. 5,290,886 and 5,397,832. These procedures
are easily applicable to the current invention.
[0108] In certain embodiments the components as well as the blends
may include various amounts of plasticizer(s). In one embodiment,
the plasticizer comprises C.sub.6 to C.sub.200 paraffins, and
C.sub.8 to C.sub.100 paraffins in another embodiment. In another
embodiment, the plasticizer consists essentially of C.sub.6 to
C.sub.200 paraffins, and consists essentially of C8 to C.sub.100
paraffins in another embodiment. For purposes of the present
invention and description herein, the term "paraffin" includes all
isomers such as n-paraffins, branched paraffins, isoparaffins, and
may include cyclic aliphatic species, and blends thereof, and may
be derived synthetically by means known in the art, or from refined
crude oil. Suitable plasticizers also include "isoparaffins",
"polyalphaolefins" (PAOs) and "polybutenes" (a subgroup of PAOs).
These three classes of compounds can be described as paraffins
which can include branched, cyclic, and normal structures, and
blends thereof. They can be described as comprising C.sub.6 to
C.sub.200 paraffins in one embodiment, and C.sub.8 to C.sub.100
paraffins in another embodiment. Preferred plasticizers include
those described in WO 2004/014998 (which is incorporated by
reference herein), particularly those plasticizers described at
page 9, line 31 to page 26, line 19. Preferred poly-alpha-olefins
(PAO's) useful in this invention include those described in WO
2004/014998, particularly those described at page 17, line 19 to
page 19, line 25. Likewise Group III Basestocks may be used as
plasticizers herein. Preferred Group III Basestocks include those
described in WO 2004/014998, particularly those Group III
Basestocks which are severely hydrotreated mineral oils having a
saturates levels of 90% or more, preferably 92% or more, preferably
94% or more, preferably 95% or more, and sulfur contents less than
0.03%, preferably between 0.001 and 0.01%, and viscosity index (VI)
is in excess of 120, preferably 130 or more. Preferably the Group
III hydrocarbon base stock has a kinematic viscosity at 100.degree.
C. of 3 to 100, preferably 4 to 100 cSt, preferably 6 to 50 cSt,
preferably 8 to 20; and/or a number average molecular weight of 300
to 5,000, preferably 400 to 2,000, more preferably 500 to 1,000;
and/or a carbon number of 20 to 400, preferably 25 to 400,
preferably 35 to 150, more preferably 40 to 100. The plasticizer
may be present in the blends of the invention from 0.1 wt % to 60
wt % in one embodiment (based upon the weight of the blend,
respectively), and from 0.5 wt % to 40 wt % in another embodiment,
and from 1 wt % to 20 wt % in yet another embodiment, and from 2 wt
% to 10 wt % in yet another embodiment, wherein a desirable range
may comprise any upper wt % limit with any lower wt % limit
described herein.
Films
[0109] In one embodiment the blends of the present invention are
formed into films. Polyolefin films are widely used; for example,
in shopping bags, pressure sensitive tape, gift wrap, labels, food
packaging, non-food packaging, medical applications, etc. Most of
these applications require high tear (in machine and transverse
directions) and impact strengths, puncture resistance, high gloss,
and low haziness. The blends described above may be formed into
monolayer or multilayer films appropriate for such applications.
These films may be formed by any of the conventional techniques
known in the art including extrusion, co-extrusion, extrusion
coating, lamination, blowing and casting. The film may be obtained
by the flat film or tubular process which may be followed by
orientation in a uniaxial direction or in two mutually
perpendicular directions in the plane of the film. One or more of
the layers of the film may be oriented in the transverse and/or
longitudinal directions to the same or different extents. This
orientation may occur before or after the individual layers are
brought together. For example a polyethylene layer can be extrusion
coated or laminated onto an oriented polypropylene layer or the
polyethylene and polypropylene can be coextruded together into a
film then oriented. Likewise, oriented polypropylene could be
laminated to oriented polyethylene or oriented polyethylene could
be coated onto polypropylene then optionally the combination could
be oriented even further. Typically the films are oriented in the
Machine Direction (MD) at a ratio of up to 15, preferably between 5
and 7, and in the Transverse Direction (TD) at a ratio of up to 15
preferably 7 to 9. However in another embodiment the film is
oriented to the same extent in both the MD and TD directions.
[0110] In another embodiment the layer comprising the blends
described herein may be combined with one or more other layers. The
other layer(s) may be any layer typically included in multilayer
film structures. For example the other layer or layers may be:
1. Polyolefins
[0111] Preferred polyolefins include homopolymers or copolymers of
C.sub.2 to C.sub.40 olefins, preferably C.sub.2 to C.sub.20
olefins, preferably a copolymer of an alpha-olefin and another
olefin or alpha-olefin (ethylene is defined to be an alpha-olefin
for purposes of this invention). Preferably homopolyethylene,
homopolypropylene, propylene copolymerized with ethylene and or
butene, ethylene copolymerized with one or more of propylene,
butene or hexene, and optional dienes. Preferred examples include
thermoplastic polymers such as ultra low density polyethylene, very
low density polyethylene, linear low density polyethylene, low
density polyethylene, medium density polyethylene, high density
polyethylene, polypropylene, isotactic polypropylene, highly
isotactic polypropylene, syndiotactic polypropylene, random
copolymer of propylene and ethylene and/or butene and/or hexene,
elastomers such as ethylene propylene rubber, ethylene propylene
diene monomer rubber, neoprene, and blends of thermoplastic
polymers and elastomers, such as for example, thermoplastic
elastomers and rubber toughened plastics.
2. Polar Polymers
[0112] Preferred polar polymers include homopolymers and copolymers
of esters, amides, acetates, anhydrides, copolymers of a C.sub.2 to
C.sub.20 olefin, such as ethylene and/or propylene and/or butene
with one or more polar monomers such as acetates, anhydrides,
esters, alcohol, and or acrylics. Preferred examples include
polyesters, polyamides, ethylene vinyl acetate copolymers, and
polyvinyl chloride.
[0113] 3. Cationic polymers Preferred cationic polymers include
polymers or copolymers of geminally disubstituted olefins,
alpha-heteroatom olefins and/or styrenic monomers. Preferred
geminally disubstituted olefins include isobutylene, isopentene,
isoheptene, isohexene, isooctene, isodecene, and isododecene.
Preferred alpha-heteroatom olefins include vinyl ether and vinyl
carbazole, preferred styrenic monomers include styrene, alkyl
styrene, para-alkyl styrene, alpha-methyl styrene, chloro-styrene,
and bromo-para-methyl styrene. Preferred examples of cationic
polymers include butyl rubber, isobutylene copolymerized with para
methyl styrene, polystyrene, and poly-alpha-methyl styrene.
4. Miscellaneous
[0114] Other preferred layers can be paper, wood, cardboard, metal,
metal foils (such as aluminum foil and tin foil), metallized
surfaces, glass (including silicon oxide (SiO.x) coatings applied
by evaporating silicon oxide onto a film surface), fabric,
spunbonded fibers and fabrics, and non-wovens (particularly
polypropylene spun bonded fibers and fabrics or non-wovens), and
substrates coated with inks, dyes, pigments, and the like.
[0115] The films may vary in thickness depending on the intended
application, however films of a thickness from 1 to 250 .mu.m are
usually suitable. Films intended for packaging are usually from 10
to 250 .mu.m thick. The thickness of the sealing layer is typically
0.2 to 50 .mu.m. There may be a sealing layer on both the inner and
outer surfaces of the film or the sealing layer may be present on
only the inner or the outer surface.
[0116] Additives such as slip, antiblock, antioxidants, pigments,
fillers, processing aids, UV stabilizers, neutralizers, lubricants,
surfactants and/or nucleating agents may also be present in one or
more than one layer in the films. Examples of useful additives
include silicon dioxide, titanium dioxide, polydimethylsiloxane,
talc, dyes, wax, calcium stearate, carbon black, low molecular
weight resins and glass beads.
[0117] In another embodiment one or more layers may be modified by
corona treatment, electron beam irradiation, gamma irradiation,
microwave irradiation, or metallizing. In a preferred embodiment
one or both of the surface layers is modified by corona
treatment.
[0118] The films described herein may also comprise from 5 to 60
weight %, based upon the weight of the polymer and the resin, of a
hydrocarbon resin. The resin may be combined with the polymer of
the seal layer(s) or may be combined with the polymer in the core
layer(s). The resin preferably has a softening point above
100.degree. C., even more preferably from 130 to 180.degree. C. The
films comprising a hydrocarbon resin may be oriented in uniaxial or
biaxial directions to the same or different degrees.
[0119] In a preferred embodiment, this invention relates to a film
comprising a layer comprising one or more of the blends above
(where the layer is 2.5 to 635 .mu.m/0.1 to 25 mils thick) where
the film has:
[0120] a haze of 10% or less,
[0121] a 10 Secant Tensile Modulus of 100,000 to 30,000 psi (690 to
207 MPa),
[0122] an Elmendorf tear in both the machine direction and
transverse direction of 45 g/mil or more (1.77 g/micron or
more),
[0123] a total energy impact of 4 J or more, and
[0124] a melt flow rate of 0.1 to 100 dg/min.
[0125] In a preferred embodiment, the films and or the layers
comprising the blends described herein are from 2.5 to 635 microns
(.mu.m) thick, preferably between 5 to 550 .mu.m thick, preferably
10 to 500 .mu.m thick, preferably between 25 to 400 .mu.m thick,
preferably 20 to 200 .mu.m thick.
[0126] The films of the present invention preferably have a haze of
10% or less, preferably 5% or less, preferably 3% or less,
preferably 2% or less, preferably 1% or less, preferably 0.5% or
less, as measured by ASTM D 1003.
[0127] In another embodiment, the films of the present invention
preferably have a 45.degree. gloss (MD and TD) of 70 or more,
preferably 75 or more, preferably 80 or more, preferably 82 or
more, preferably 85 or more, preferably 90 or more, as measured by
ASTM D 2457 at an angle of 45.degree., unless otherwise stated.
[0128] In another embodiment, the films of the present invention
have low modulus (high degree of softness); preferably have
1.degree. Secant tensile Modulus (as measured by ASTM D 882) of
125,000 psi to 100,000 psi (690 to 860 MPa), preferably 125,000 psi
to 50,000 psi, (345 to 860 MPa), preferably 125,000 to 30,000 psi
(205 to 860 MPa).
[0129] In another embodiment, the films of the present invention
preferably have an Elmendorf tear in the machine direction (MD) of
45 g/mil or more (1.77 g/micron or more), preferably 45 g/mil to 75
g/mil (1.77 to 2.95 g/.mu.m), preferably 45 g/mil to 100 g/mil
(1.77 to 3.94 g/.mu.m), preferably 45 g/mil to 120 g/mil (1.77 to
4.72 g/[m), as determined by ASTM D1922, and normalized by the
average film thickness in mil (0.001 in or 25.4/.mu.m).
[0130] In another embodiment, the films of the present invention
preferably have a total energy impact (ASTM D 4272-99) of 3 ft.lb
or more (4 J or more), preferably 2 to 6 ft.lb or more (2.7 to 8.1
J).
[0131] In another embodiment, the films of the present invention
preferably have a Ultimate Tensile Strength, and (as determined by
ASTM D882.) of 6000 psi or more (41.4 MPa) along both MD and
TD.
[0132] In another embodiment, the films of the present invention
preferably have a Elongation at Break) (as determined by ASTM
D882.) of 600% or more along both MD and TD.
[0133] In another embodiment, the films of the present invention
preferably have a Puncture Energy of 25 in.lb/mil (0.11 J/.mu.m) or
more as measured according to ASTM D5748-95 except that i) a 0.75
inch diameter elongated stainless steel probe with matted finish,
instead of a 0.75 inch diameter pear shaped TFE-fluorocarbon coated
probe was used, and ii) an average gauge value was used for all the
test specimens, instead of separate gauge measurements on each test
specimen.
[0134] In another embodiment, the films of the present invention
preferably have a Puncture resistance of 8 lb/mil (1.4 N/.mu.m) or
more as measured according to ASTM D 5748-95, except for the
measurement modifications noted in the previous paragraph.
[0135] The blends of this invention can be used in application
areas requiring soft films, such as those used in diapers. The good
tear propagation resistance and total energy impact resistance,
coupled with the low haze, offer broad opportunities in packaging
films.
[0136] In additional embodiments, this invention relates to:
1. A film comprising a heterogeneous blend of:
[0137] 1) from 60 to 99 weight percent of one or more
semi-crystalline polymers (based upon the weight of the
semi-crystalline and semi-amorphous polymers), each
semi-crystalline polymer comprising propylene and from 0 to 5
weight % alpha-olefin comonomer (based upon the weight of the
polymer), said semi-crystalline polymers each having a melting
point between 100 and 170.degree. C. and a melt flow rate of 200
dg/min or less; and
[0138] 2) from 1 to 40 weight % of one or more semi-amorphous
polymers (based upon the weight of the semi-crystalline and
semi-amorphous polymers), each semi-amorphous polymer comprising
propylene and from 10 to 25 weight % of one or more C2 and or C4 to
C10 alpha-olefin comonomers, said semi-amorphous polymers each
having:
[0139] a) heat of fusion of 4 to 70 J/g;
[0140] b) a melt flow rate of 0.1 to 200 dg/min;
[0141] c) an intermolecular composition distribution as determined
by thermal fractionation in hexane such that 85% by weight or more
of the polymer is isolated as one or two adjacent, soluble
fractions with the balance of the polymer in immediately preceding
or succeeding fractions; and wherein each of these fractions has a
wt % comonomer content with a difference of no greater than 20 wt %
relative to the average wt % comonomer content of the
copolymer;
[0142] d) an Mw/Mn of 1.5 to 4,
[0143] e) a propylene triad tacticity, as measured by .sup.13C NMR,
of 75% or greater;
where the blend has:
[0144] i) a melt flow rate of 0.5 to 100 dg/min; and
[0145] ii) 0 to 5 weight % filler, based upon the weight of the
polymers and the filler; and
[0146] iii) a haze of 20% or less measured on a 1 mm thick
injection molded chip; and
[0147] iv) a permanent set of greater than 65%; and
where the film is 0.1 to 25 mil (2.5 to 635 micron) thick and
has:
[0148] a haze of 10% or less,
[0149] a 1.degree. Secant tensile modulus of 100,000 to 30,000
psi,
[0150] an Elmendorf tear in the machine direction of 45 g/mil or
more,
[0151] an Elmendorf tear in the transverse direction of 45 g/mil or
more,
[0152] a total energy impact of 3 J or more; and
[0153] a 45 degree gloss of 82 or more.
2. The film of paragraph 1 wherein the semi-crystalline polymer
comprises propylene and from 1 to 3 weight % of a C2 to C10 alpha
olefin comonomer.
3. The film of paragraph 2 wherein the alpha-olefin comonomer is
selected from the group consisting of ethylene, butene, pentene,
hexene, heptene, octene, nonene, and decene.
4. The film of paragraph 2 wherein the alpha-olefin comonomer is
selected from the group consisting of ethylene, butene, hexene, and
octene.
5. The film of paragraph 2 wherein the alpha-olefin comonomer is
ethylene.
6. The film of paragraph 1 wherein the semi-crystalline polymer
comprises 0 weight % comonomer.
7. The film of any of the above paragraphs wherein the
semi-crystalline polymer has a melting point of 120 to 170.degree.
C.
8. The film of any of the above paragraphs wherein the
semi-crystalline polymer has an Mw/Mn between 1.5 and 4.
9. The film of any of the above paragraphs wherein the
semi-amorphous polymer comprises propylene and from 10 to 20 weight
% of a C2 to C10 alpha olefin comonomer.
10. The film of paragraph 9 wherein the alpha-olefin comonomer is
selected from the group consisting of ethylene, butene, pentene,
hexene, heptene, octene, nonene, and decene.
11. The film of paragraph 9 wherein the alpha-olefin comonomer is
selected from the group consisting of ethylene, butene, hexene, and
octene.
12. The film of paragraph 9 wherein the alpha-olefin comonomer is
ethylene.
13. The film of any of the above paragraphs wherein the
semi-amorphous polymer has a percent crystallinity of between 2 and
25%.
14. The film of any of the above paragraphs wherein the
semi-amorphous polymer has a melt flow rate of 1 to 25 dg/min.
15. The film of any of the above paragraphs wherein the
semi-amorphous polymer has a melting point between 30 and
80.degree. C.
16. The film of any of the above paragraphs wherein the
semi-amorphous polymer has a tacticity index of from 4 to 12.
17. The film of any of the above paragraphs wherein the
semi-amorphous polymer has a propylene triad tacticity of 80% or
greater, preferably 85% or greater, preferably 90% or greater.
18. The film of any of the above paragraphs where the blend has a
haze of 15% or less, preferably 12% or less, preferably 10% or
less.
19. The film of any of the above paragraphs where the film has a
gloss of 85 units or more, preferably 89 or more, preferably 90 or
more.
[0154] 20. The film of any of the above paragraphs wherein the
semi-amorphous polymer comprises from 11 to 25 weight % comonomer
and is present at from 15 to 40 weight %, and wherein the blend has
dispersions of semi-amorphous polymer less than 4 .mu.m in size in
a continuous phase of semi-crystalline polymer and wherein the film
has machine direction Elmendorf tear of 60 g/mil (2.4 g/.mu.m) or
more, haze of 2% or less, 45 degree gloss of 87 unit or higher, 1%
secant tensile modulus of 75,000 psi (517 MPa) or lower, and total
energy impact of 3 J or more.
[0155] 21. The film of any of paragraphs 1 to 19 wherein the
semi-amorphous polymer comprises from 11 to 25 weight % comonomer
and is present at from 25 to 40 weight %, and wherein the blend has
dispersions of semi-amorphous polymer less than 4 .mu.m in size in
a continuous phase of semi-crystalline polymer and wherein the film
has machine direction Elmendorf tear of 100 g/mil (2.4 g/.mu.m) or
more, haze of 1.5% or less, 45 degree gloss of 88 unit or higher,
1% secant tensile modulus of 50,000 psi (517 MPa) or lower, and
total energy impact of 7 J or more.
22. The film of any of the above paragraphs wherein the blend has a
permanent set of 165% or more, preferably 175% or more, preferably
200% or more.
23. The film of any of the above paragraphs wherein a 3.18 mm thick
injection molded pad of the blend has a resistance to stress
whitening of Hunter color .DELTA.L of 20 or less, preferably 15 or
less, preferably 10 or less, preferably 5 or less.
24. The film of any of the above paragraphs wherein the film has a
haze of 4% or less, preferably 3% or less, preferably 2% or
less.
25. The film of paragraph 23 wherein the film has a haze of 5% or
less, an MD Elmendorf tear of 50 g/mil or more and a total energy
impact of 3 J or more.
26. The film of paragraph 23 wherein the film has a haze of 2% or
less, an MD Elmendorf tear of 100 g/mil or more and a total energy
impact of 7 J or more.
27. The film of any of the above paragraphs wherein the film
has:
[0156] a) a haze of 2% or less;
[0157] b) a machine direction tensile strength at break of greater
than 40 MPa;
[0158] c) a transverse direction tensile strength at break of
greater than 40 MPa;
[0159] d) a machine direction elongation at break of greater than
500%;
[0160] e) a transverse direction elongation at break of greater
than 500%;
[0161] f) a machine direction Elmendorf tear of 50 to 150
g/mil;
[0162] g) a transverse direction Elmendorf tear of 100 to 400
g/mil;
[0163] h) a puncture resistance of 6 to 10 lb/mil; and
[0164] i) a machine direction tensile modulus of less than 350
MPa.
28. The film of any of the above paragraphs where the film is a
cast film, a blown film, or a laminated film.
29. The film of any of the above paragraphs wherein the film is
coextruded, or laminated.
30. The film of any of the above paragraphs wherein the film
comprises two or more layers.
31. The film of any of the above paragraphs wherein the film
comprises a core layer comprising the heterogeneous blend.
32. The film of any of the above paragraphs wherein the film
comprises a skin layer comprising the heterogeneous blend.
33. The film of any of the above paragraphs wherein the blend of
the semi-amorphous and semi-crystalline polymers further comprises
plasticizer, preferably poly-alphaolefin, preferably
polydecene.
34. The film any of the above paragraphs wherein the heterogeneous
blend further comprises slip agent, preferably 50 to 5000 ppm of an
amides having the chemical structure
CH.sub.3(CH.sub.2).sub.7CH.dbd.CH(CH.sub.2).sub.xCONH.sub.2 where x
is 5 to 15.
[0165] 35. The film of any of the above paragraphs wherein the
heterogeneous blend further comprises a clarifying agent,
preferably the clarifying agent is present at 10 ppm to 10 weight %
(more preferably 25 ppm to 5 weight %, preferably 50 ppm to 4000
ppm, based on total polymer in the blend composition) of an
organophosphate, phosphate ester, sodium benzoate, talc, sorbitol,
adipic acid, benzoic acid, (or metal salts of these acids),
inorganic fillers, preferably the clarifying agent is a
sorbitol-based agents, aluminum salt based agents, or sodium salt
based agents, or a Ziegler-Natta olefin product or other highly
crystalline polymers, preferably the clarifying agent is
disodium[2.2.1]heptane bicyclodicarboxylate, bis(3,4
dimethylbenzylidene)sorbitol, sodium
2,2'-methylene-bis(4,6-di-tert-butylphenyl)phosphate, (p-chloro,
p'methyl)dibenzylidene sorbitol, bis(p-ethylbenzylidene)sorbitol,
1,2,3,4-dibenzylidene sorbitol, 1,2,3,4-d]-para-methylbenzylidene
sorbitol, and or aluminum
2,2'-methylene-bis(4,6-di-tert-butylphenyl)phosphate.
[0166] 36. The film of any of paragraphs 1 to 35 wherein the
semi-amorphous polymer has an intermolecular composition
distribution of 85% ore more, preferably 90% or more by weight of
the polymer isolated as one or two adjacent, soluble fractions with
the balance of the polymer in immediately preceding or succeeding
fractions; and wherein each of these fractions has a weight %
comonomer content with a difference of no greater than 20 wt %
(relative) of the average weight % comonomer of the copolymer,
preferably no greater than 10%.
[0167] 37. The film of any of the above paragraphs wherein the
blend has dispersions of semi-amorphous polymer less than 4 .mu.m
in size in a continuous phase of semi-crystalline polymer,
preferably less than 3 .mu.m in size, preferably less than 2 .mu.m
in size, preferably less than 1 .mu.m in size.
38. The film of any of the above paragraphs wherein the film has a
haze of 1% or less.
39. The film of any of the above paragraphs wherein the film is
laminated to a substrate, preferably the substrate is a non-woven
fabric, paper, a polyolefin, wood, cardboard, metals, metal foils,
metallized surfaces, glass, and or glass coatings.
40. The film of any of the above paragraphs wherein the film is
laminated to a substrate, where the substrate is coated with ink,
dye, and or pigment.
41. A package comprising the film of any of the above
paragraphs.
42. A diaper, medical film or packaging film comprising the film of
any of paragraphs 1 to 40.
EXAMPLES
Mw, Mn, Mz were measured by Gel Permeation Chromatography, as
described above.
Mooney Viscosity is measured according to ASTM D 1646.
Melt flow rate (MFR) was measured according to ASTM D 1238
condition L at 230.degree. C. under a load of 2.16 kg.
[0168] Ethylene weight % was measured as follows. A thin
homogeneous film was pressed at a temperature of about 150.degree.
C. or greater, then mounted on a Perkin Elmer PE 1760 infrared
spectrophotometer. A full spectrum of the sample from 600 cm.sup.-1
to 4000 cm.sup.-1 was recorded and the monomer weight percent of
ethylene was calculated according to the following equation:
Ethylene wt %=82.585-111.987X+30.045 X.sup.2, wherein X is the
ratio of the peak height at 1155 cm.sup.-1 and peak height at
either 722 cm.sup.-1 or 732 cm.sup.-1, whichever is higher.
[0169] Glass Transition Temperature (Tg), .beta. relaxation, Loss
Modulus (E'') and Storage Modulus (E') were measured by dynamic
mechanical thermal analysis (DMTA). The instrument used was the RSA
II, Rheometrics Solid Analyzer II from TA Instruments, New Castle,
Del. The instrument was operated in tension mode and used molded
rectangular samples. Sample conditions were: 0.1% strain, 1 Hz
frequency, and 2 degree C. per minute heating rate, covering the
temperature range from -135 C to the melting point of the sample.
Samples were molded at about 200 C. Typical sample dimensions were
23 mm length.times.6.4 mm width x thickness between 0.25 mm and 0.7
mm, depending on the sample. tan .delta. is the ratio of E''/E',
where E' is the Storage Modulus and E'' is the Loss Modulus. The
output of these DMTA experiments is the storage modulus (E') and
loss modulus (E''). The storage modulus measures the elastic
response or the ability of the material to store energy, and the
loss modulus measures the viscous response or the ability of the
material to dissipate energy. The ratio of E''/E' (=tan[.delta.])
gives a measure of the damping ability of the material. Energy
dissipation mechanisms (i.e., relaxation modes) show up as peaks in
tan[6], and are associated with a drop in E' as a function of
temperature. The uncertainty associated with reported values of E'
is expected to be on the order of .+-.10%, due to variability
introduced by the molding process.
[0170] Crystallization temperature (Tc), melting temperature
(T.sub.m) and heat of fusion (Hf. .DELTA.H, or .DELTA.Hf) were
measured using Differential Scanning Calorimetry (DSC). This
analysis was conducted using either a TA Instruments MDSC 2920 or a
Perkin Elmer DSC7. Typically, 6 to 10 mg of molded polymer or
plasticized polymer was sealed in an aluminum pan and loaded into
the instrument at room temperature. Melting data (first heat) were
acquired by heating the sample to at least 30.degree. C. above its
melting temperature at a heating rate of 10.degree. C./min. This
provides information on the melting behavior under as-molded
conditions, which can be influenced by thermal history as well as
any molded-in orientation or stresses. The sample was then held for
10 minutes at this temperature to destroy its thermal history.
Crystallization data was acquired by cooling the sample from the
melt to at least 50.degree. C. below the crystallization
temperature at a cooling rate of 10.degree. C./min. Typically, the
blend samples were cooled down to -25 C. The sample was then held
at this temperature for 10 minutes, and finally heated at
110.degree. C./min to acquire additional melting data (second
heat). The melting temperatures reported in the tables are the peak
melting temperatures from the second heat unless otherwise
indicated. For polymers displaying multiple peaks, the higher
melting peak temperature is reported. Areas under the curve were
used to determine the heat of fusion (.DELTA.H.sub.f) which can be
used to calculate the degree of crystallinity. A value of 189 J/g
was used as the equilibrium heat of fusion for 100% crystalline
polypropylene. The percent crystallinity of a propylene polymer is
calculated using the formula, [area under the curve (J/g)/189
(J/g)]*100.
[0171] Haze o the blend was measured according to ASTM D 1003
including that 2500 ppm of bis(3,4 dimethylbenzylidene)sorbitol
(Millad 3988) was added to the blend prior to forming the blend
into the molded 1 mm chip. Haze of the film was measured according
to ASTM D 1003.
[0172] Gloss was measured according to ASTM D 2457 at a 45.degree.
angle.
Example 1
Copolymerization to Form the Semi-Amorphous Propylene-Ethylene
Copolymers (SAPEC)
[0173] Continuous polymerization was conducted in a 9 liter
continuous flow stirred tank reactor using hexane as the solvent.
The liquid full reactor had a residence time of 9 minutes and the
pressure was maintained at 700 kPa. A mixed feed of hexane,
ethylene and propylene was pre-chilled to approximately -30.degree.
C. to remove the heat of polymerization, before entering the
reactor. A solution of catalyst/activator in toluene and the
scavenger in hexane were separately and continuously admitted into
the reactor to initiate the polymerization. The reactor temperature
was maintained between 35 and 50.degree. C., depending on the
target molecular weight. The feed temperature was varied, depending
on the polymerization rate to maintain a constant reactor
temperature. The polymerization rate was varied from 0.5 kg/hr to 4
kg/hr. Hexane at 30 kg/hr was mixed with ethylene at 717 g/hr and
propylene at 5.14 kg/hr and fed to the reactor. The polymerization
catalyst, dimethyl silyl bis-indenyl hafnium dimethyl activated in
a 1:1 molar ratio with N',N'-dimethyl anilinium-tetrakis
(pentafluorophenyl)borate was introduced at the rate of 0.0135
g/hr. A dilute solution of triisobutyl aluminum was introduced into
the reactor as a scavenger of catalyst terminators at a rate of
approximately 111 mole of scavenger per mole of catalyst. After
five residence times of steady polymerization, a representative
sample of the polymer produced in this polymerization was
collected. The solution of the polymer was withdrawn from the top
and then steam distilled to isolate the polymer. The polymerization
rate was measured at 3.7 kg/hr. The polymer produced in this
polymerization had an ethylene content of 14%, Mooney viscosity ML
(1+4) at 125.degree. C. of 13.1 and had isotactic propylene
sequences. Variations in the composition of the polymer were
obtained principally by changing the ratio of ethylene to
propylene. Molecular weight of the polymer was varied by either
changing the reactor temperature or by changing the ratio of total
monomer feed rate to the polymerization rate. Dienes for
terpolymerization were added to the mixed feed stream entering the
reactor by preparing the diene in a hexane solution and metering it
in the required volumetric amount.
[0174] In the manner described in Example 1 above, several
semi-amorphous propylene-ethylene copolymers (SAPEC) were
synthesized. These are described in Table 1. Samples SAPEC-1 and 2
were utilized to prepare the blends to fabricate films.
TABLE-US-00002 TABLE 1 Characterization of Semi-Amorphous
Propylene-Ethylene Copolymers ML(1 + 4) Ethylene .DELTA.H melt
SAPEC at 125 C Mw.sup.# Mn.sup.# Mz.sup.# Wt %* Tm dsc .degree. C.
J/g SAPEC-1 2.5** 227111 130615 349440 14.9 50.9 14.6 SAPEC-2 2.2**
247620 139049 388319 16.2 51.5 9.8 SAPEC-3 14 248900 102000 7.3
84.7 SAPEC-4 23.9 265900 124700 11.6 43.0 SAPEC-5 33.1 318900
121900 16.4 42.2 SAPEC-6 34.5 11.1 63.4 SAPEC-7 38.4 14.7 47.8
**MFR values (dg/min) by ASTM D-1238 Cond L .sup.#GPC data in
daltons *Ethylene wt % measured by IR procedure described
earlier.
[0175] The semi-amorphous propylene-ethylene copolymers, which are
derived from chiral metallocene-based catalysts, have a narrow
inter and intramolecular composition distribution. The
intermolecular composition distribution of the polymer was
determined by thermal fractionation in hexane as follows: about 30
g of the crystallizable propylene-ethylene copolymer was cut into
small cubes about 1/8th inch (0.32 cm) on the side and then
introduced into a thick-walled glass bottle closed with screw cap
along with 50 mg of Irganox 1076 antioxidant (Ciba-Geigy Corpn).
425 ml of hexane (a principal mixture of normal and iso-isomers)
was added to the contents of the bottle and the sealed bottle was
maintained at 23.degree. C. for 24 hours. At the end of this
period, the solution was decanted and the residue was treated with
additional hexane for an additional 24 hours. At the end of this
period, the two hexane solutions were combined and evaporated to
yield a residue of the polymer soluble at 23.degree. C. To the
residue was added sufficient hexane to bring the volume to 425 ml
and the bottle was maintained at 31.degree. C. for 24 hours in a
covered circulating water bath. The soluble polymer was decanted
and an additional amount of hexane is added for another 24 hours at
31.degree. C., prior to decanting. In this manner, fractions of the
semi-amorphous propylene-ethylene copolymer soluble at 40.degree.
C., 48.degree. C., 55.degree. C. and 62.degree. C. were obtained,
at temperature increases of approximately 8.degree. C. between
stages. The soluble polymers were dried, weighed and analyzed for
composition, as wt % ethylene content, by the IR technique
described above. Soluble fractions obtained in the adjacent
temperature increases are the adjacent fractions in the
specification above. Data on different representative
semi-amorphous propylene-ethylene copolymers are shown in Tables 2
and 3. EPR in Table 2 is an ethylene propylene rubber that does not
contain crystallizable propylene species like the semi-amorphous
copolymers. This EPR has 47% ethylene, a Mooney viscosity (ML 1+8
at 127 C) of 28 and a GPC polydispersity (Mw/Mn) of 2.3. It was
obtained under the tradename Vistalon.TM. 457--by ExxonMobil
Chemical in Houston, Tex. TABLE-US-00003 TABLE 2 Solubility of
Fractions of SAPEC's Fraction 1- Fraction 4- Wt % Fraction 2-
Fraction 3- Wt % soluble Wt % soluble Wt % soluble soluble SAPEC at
23.degree. C. at 31.degree. C. at 40.degree. C. at 48.degree. C.
SAPEC-3 1.0 2.9 28.3 68.5 SAPEC-4 6.5 95.7 -- -- SAPEC-5 51.6 52.3
-- -- SAPEC-6 18.7 83.6 -- -- SAPEC-7 36.5 64.2 -- -- EPR 101.7 --
-- -- Note: The sum of the fractions may in some cases add up to
slightly greater than 100, due to imperfect drying of the polymer
fractions.
[0176] TABLE-US-00004 TABLE 3 Composition of Fractions of SAPEC's
obtained in Table 2 Wt % Wt % ethylene Wt % ethylene Wt % ethylene
ethylene SAPEC in Fraction 1 in Fraction 2 in Fraction 3 in
Fraction 4 SAPEC-3 8.0 7.6 SAPEC-4 12.0 11.2 -- -- SAPEC-5 16.8
16.5 -- -- SAPEC-6 13.2 11.2 -- -- SAPEC-7 14.9 14.6 -- -- EPR 46.8
Note: Only fractions with more than 4% of the total mass of the
polymer in Table 2 are analyzed for composition. The experimental
accuracy in determination of the ethylene content is believed to be
within about 0.4% absolute.
The above semi-amorphous propylene-ethylene copolymers SAPEC-1 and
SAPEC-2 were combined with a metallocene-based propylene
homopolymer to produce the blend compositions, as will be described
later. SAPEC-1 and SAPEC-2 were first visbroken to reach an MFR of
about 20 prior to melt blending with polypropylene. Visbreaking is
a widely used and well-accepted procedure to increase the melt flow
rate of propylene polymers. The procedure typically involves melt
compounding the propylene polymer in the presence of a specific
amount of a peroxide [e.g. (2,5 dimethyl-2,5-di(t-butyl
peroxy)hexane) available as Luperox 101 from AtoFina, Organic
Peroxides Divn., Philadelphia, Pa.]. The amount is dependent on the
degree of MFR increase desired. The visbreaking was done in the
presence of some polypropylene (60/40 blend of the SAPEC and a
metallocene-based propylene homopolymer) to provide additional
crystallinity. The presence of the polypropylene aids in the
extrusion compounding step by providing rapid solidification of the
extruded strands in the water bath, easier chopping of the strands
into pellets and free movement of the pellets through transfer
lines.
Example 2
Visbreaking of Semi-Amorphous Propylene-Ethylene Copolymers SAPEC-1
and -SAPEC-2
[0177] The polymer used along with the semi-amorphous
propylene-ethylene copolymers during visbreaking was a propylene
homopolymer, having an MFR of 7.5 dg/min and an Mw of 195,000
produced using a metallocene catalyst, namely, rac di-methyl
siladiyl bis-(2-methyl, 4-phenyl indenyl) zirconium dimethyl
activated with a silica bound activator of N,N-di-ethyl aniline
tris(perfluorophenyl)boron in a pilot scale, two reactor,
continuous, stirred tank, bulk liquid-phase process. In the
catalyst, the zirconium loading was about 0.117 wt % and the boron
loading about 0.12 wt %. The reactors were equipped with jackets
for removing the heat of polymerization. The reactor temperature
was set at 74.degree. C. (165 F) in the lead reactor and 68.degree.
C. (155 F) in the tail reactor. Catalyst was fed at a rate of 1.2
g/hr. Tri-ethyl aluminum (TEAL; fed to the reactor as a 1 wt %
solution in hexane solvent) was used as scavenger at a level of 20
ppm. The catalyst and silica bound activator, described above, were
fed as a 10% slurry in mineral oil and were flushed into the
reactor with propylene. Propylene monomer was fed into the lead
reactor at a rate of 79.5 kg/hr (175 lb/hr) and to the tail reactor
at a rate of 30 kg/hr (65 lb/hr). Hydrogen was added for molecular
weight control at 1970 mppm in the lead reactor and 2220 mppm in
the tail reactor. Polymer production rates were 20.5 kg/hr (45
lb/hr) in the lead reactor and 10 kg/hr (22 lb/hr) in the tail
reactor. The reactor product was routed through a granules-handling
system to separate and recover the final polymer product. The
polymer discharged from the reactors had an MFR of 7.5 dg/min (GPC
Mw 195,000, Mw/Mn 2.0, Mz/Mw 1.54). 68% of the final polymer
product was derived from the first stage and 32% of the final
product was derived from the second stage. The polymer was melt
homogenized with 1500 ppm of Irganox-2215 (Ciba-Geigy Corporation)
and pelletized. Visbreaking was conducted on blends of SAPEC-1 and
SAPEC-2 with the 7.5 MFR propylene homopolymer discussed above. The
blend ratio was 60 wt % SAPEC and 40 wt % propylene homopolymer.
The visbreaking was carried out on a Reifenhauser extruder equipped
with a single screw (60 mm screw diameter; 24:1 L/D ratio; mixing
screw). A summary of the visbreaking experiments is shown in Table
4. TABLE-US-00005 TABLE 4 Visbreaking of Blends of SAPEC-1 and
SAPEC-2 with Propylene Homopolymer (60 wt %/40 wt %) Post treatment
Example Copolymer Peroxide (ppm) MFR dg/min Example 2-1 SAPEC-1 800
20.0 Example 2-2 SAPEC-2 950 30.0
Both products, Examples 2-1 and 2-2, contained 60 wt % of
semi-amorphous propylene-ethylene copolymer. Examples 2-1 and 2-2
were then used to prepare additional blends containing different
amounts of semi-amorphous propylene-ethylene copolymer.
Example 3
Preparation of Blends of Semi-Amorphous Propylene-Ethylene
Copolymer and Propylene Homopolymer
[0178] Example 2-1 and Example 2-2 were melt mixed with a
metallocene-based propylene homopolymer having an MFR of 24 dg/min
(ASTM 1238 2.16 kg, 230.degree. C.), a density of 0.9 g/cc (ASTM D
792), and an Mw/Mn of 2 available from ExxonMobil Chemical Company
in Houston, Tex. under the tradename ACHIEVE.TM. 3854 to produce
several blends, shown in Table 5. TABLE-US-00006 TABLE 5
Description of Final Blends of Ex 2-1 and Ex 2-2 and Achieve 3854
MFR Achieve dg/min Wt % ethylene Ex-2-1 wt % Ex-2-2 wt % 3854 wt %
of blend in blend Example 55.5 (33.3 wt % 44.5 23.6 5.4 3-1 SAPEC2
and 22.2 wt % PP) Example 25 (15 wt % SAPEC-2 75 22.0 2.4 3-2 and
10 wt % PP) Example 45.75 (27.5 wt % 54.25 21.2 4.1 3-3 SAPEC 1 and
18.25 wt % PP) Note: PP refers to the 7.5 dg/min MFR metallocene
homopolymer used during the visbreaking operation.
Polymer blend Examples 3-1 (33.3 wt % of semi-amorphous
propylene-ethylene copolymer), 3-2 (15 wt % semi-amorphous
propylene-ethylene copolymer) and 3-3 (27.5 wt % semi-amorphous
propylene-ethylene copolymer) are all based on semi-amorphous
propylene-ethylene copolymers that contain upwards of 14 wt %,
ethylene (SAPEC-1 and SAPEC-2 in Table 1). This is higher than the
.about.12 wt % ethylene limit, beyond which the propylene-ethylene
copolymers are believed to become immiscible in blends with
polypropylene. This immiscibility leads to heterogeneous blends,
with the semi-amorphous propylene-ethylene copolymers being finely
dispersed in a matrix of polypropylene. A representation of this is
shown in FIG. 1, which is a plot of tan .delta. (E''/E' from DMTA
measurements) versus temperature for blend polymer similar to
Example 3-3. The blend comprised 33.3 wt % of a semi-amorphous
propylene-ethylene copolymer, containing 14.9 wt % ethylene, with
66.7 wt % of a semi-crystalline propylene homopolymer. The
semi-amorphous propylene-ethylene copolymer is the same as used in
Example 3-3 (viz. SAPEC-1). The figure shows the tan .delta.
response in the region of the .beta. relaxation (ie. Tg). Two
distinct peaks are observed, corresponding to the respective Tgs of
the polypropylene (at 0.degree. C.) and the semi-amorphous
propylene-ethylene copolymer (-25.degree. C.). In blend polymer
Examples 3-2 and 3-1, the SAPEC component (viz. SAPEC-2) contains
an even higher level of ethylene than Example 3-3 (16.2 wt %
ethylene versus 14.9 wt % ethylene). As a consequence, a similar 2
peak tan .delta. response is expected. This observation of two tan
.delta. response peaks, corresponding to the respective Tg
temperatures of the semi-amorphous and semi-crystalline polymers,
is an indication of the heterogeneous nature of the inventive
blends. Further demonstration of the heterogeneous nature of the
inventive blends can be seen in the AFM micrograph shown in FIG. 2.
The blend in this figure comprises 20 wt % of a semi-amorphous
propylene-ethylene copolymer, containing 14.5 wt % ethylene, with
80 wt % of a semi-crystalline propylene homopolymer. The micrograph
shows a finely dispersed semi-amorphous propylene-ethylene
copolymer (dark phase) in a matrix of the semi-crystalline polymer
(light phase).
[0179] Permanent set measurements, by the procedure described
earlier, were conducted on a blend composition comprising 33.3 wt %
of semi-amorphous propylene-ethylene copolymer and 66.7 wt % of
semi-crystalline polymer. The semi-amorphous propylene-ethylene
copolymer contained 14.5 wt % ethylene, comparable to SAPEC-1 (14.9
wt % ethylene). This blend had a mean permanent set (average for
two specimens, each over two hysterisis cycles on an Instron
machine) of 187.5%. A second measurement was conducted on a blend
with 40 wt % of the above semi-amorphous propylene-ethylene
copolymer and 60 wt % of semi-crystalline polymer. The mean
permanent set for this blend was 166.5%. These high permanent set
values confirm the non-elastic nature of the inventive blends.
Example 4
Copolymerization to Form Metallocene-Based Random Copolymer
[0180] The metallocene-based random copolymer used as a
comparator--for the semi-amorphous propylene-ethylene copolymers
blends, was a propylene copolymer, having an MFR of 6.4 dg/min and
an Mw of 224,000 produced using a metallocene catalyst, namely,
rac-di-methyl siladiyl bis-(2-methyl, 4-phenyl indenyl) zirconium
dimethyl activated with a silica bound activator of N,N-di-ethyl
aniline tris(perfluorophenyl)boron in a pilot scale, two reactor,
continuous, stirred tank, bulk liquid-phase process. In the
catalyst, the zirconium loading was about 0.117 wt % and the boron
loading about 0.12 wt %. The reactors were equipped with jackets
for removing the heat of polymerization. The reactor temperature
was set at 64.degree. C. (148 F) in the lead reactor and 59.degree.
C. (138 F) in the tail reactor. Catalyst was fed at a rate of 1.7
g/hr. Tri-ethyl aluminum (TEAL; fed to the reactor as a 1 wt %
solution in hexane solvent) was used as scavenger at a level of 20
ppm. The catalyst and silica bound activator, described above, were
fed as a 10% slurry in mineral oil and were flushed into the
reactor with propylene. Propylene monomer was fed into the lead
reactor at a rate of 79.5 kg/hr (175 lb/hr) and to the tail reactor
at a rate of 30 kg/hr (65 lb/hr). Ethylene was fed to both reactors
and the vapor phase concentration of ethylene in both reactors was
about 10 mole %. Hydrogen was added for molecular weight control at
1129 mppm in the lead reactor and 1641 mppm in the tail reactor.
Polymer production rates were 18.0 kg/hr (39.5 lb/hr) in the lead
reactor and 6.4 kg/hr (14.1 lb/hr) in the tail reactor. The reactor
product was routed through a granules-handling system to separate
and recover the final polymer product. The polymer discharged from
the reactors had an MFR of 6.4 dg/min (GPC Mw 224,000, Mw/Mn 2.0,
Mz/Mw 1.68). The ethylene incorporation was measured as 3.3 wt % in
the lead reactor product and 3.1 wt % in the tail reactor product.
Ethylene measured in the final blended product was 3.2 wt %. 74% of
the final polymer product was derived from the first stage and 26%
of the final product was derived from the second stage. The polymer
showed a DSC melting peak at 127.8.degree. C. and a DSC
crystallization peak at 91.23.degree. C. The polymer was melt
homogenized with 500 ppm of Irganox-2215 (Ciba-Geigy Corporation)
and 300 ppm of DHT-4A neutralizer (Kyowa Chemical Industry Co.,
Ltd., Osaka, Japan) and vis-broken on an extruder, as previously
described, to a final MFR of 24, from the starting MFR of 6.4. The
final visbroken product at 24 MFR was used as a control during film
fabrication and film testing and labeled as Example 4.
Example 5
Ziegler-Natta-Based Random Copolymers
[0181] Granules of random copolymer (from a standard commercial
Ziegler-Natta catalyst; 2nd generation, unsupported catalyst)
produced in a commercial reactor, were used as the starting
material to prepare a Ziegler-Natta RCP control. The product
contained 3.0 wt % ethylene as comonomer. These granules were melt
homogenized with 500 ppm of Irganox-2215 (Ciba-Geigy Corporation)
stabilizer and 300 ppm of DHT-4A neutralizer (Kyowa chemical
Industry Co., Ltd., Osaka, Japan) and again visbroken on an
extruder as outlined previously from an MFR .about.1.0 to 24 MFR.
This 24 MFR, 3.0 wt % ethylene copolymer, labeled as Example 5-1,
served as one Ziegler-Natta control.
[0182] The other Ziegler-Natta random copolymer control was PD9282
E2, from ExxonMobil Chemical Company, Houston, Tex. This commercial
product is made from a standard, supported Ziegler-Natta catalyst.
It is a 5.0 MFR propylene copolymer and contains 5.0 wt % ethylene.
It typically has a DSC melting point of 133.degree. C. It contains
an additive package of 1800 ppm Irganox-1010 stabilizer (Ciba-Geigy
Corporation), 300 ppm DHT-4A neutralizer and 1000 ppm antiblock.
PD9282 E2 was labeled as Example 5-2.
Example 6
Ziegler-Natta-Based Impact Copolymers
[0183] As an example of a conventional heterogeneous propylene
copolymer composition, Ziegler-Natta impact copolymer PP7623 E7 was
selected as control. This product has an MFR of 7.5 dg/min and
total ethylene content of 9 wt %. It contains 600 ppm of Irganox
1010 stabilizer, 600 ppm Irgafos-168 stabilizer and 300 ppm of
DHT-4A neutralizer. It is available from ExxonMobil Chemical
Company, Houston, Tex. PP7623 E7 was labeled as Example 6-1.
[0184] A summary of the Example polymers used to form film is shown
in Table 6. In addition to the three heterogeneous
SAPEC--polypropylene blends, two Ziegler-Natta RCPs and one
Ziegler-Natta ICP discussed above, metallocene homopolymer ACHIEVE
3854 (24 MFR; control) was also evaluated. ACHIEVE 3854 is a
metallocene-based propylene homopolymer having an MFR of 24 dg/min
(ASTM 1238 Condition L, 2.16 kg, 230.degree. C.), a density of 0.9
g/cc (ASTM D 792), and an Mw/Mn of about 2, available from
ExxonMobil Chemical Company in Houston, Tex. TABLE-US-00007 TABLE 6
Summary of Polymers used to fabricate Films MFR Total Ethylene
Polymer type (dg/min) (wt %) Example 3-1 SAPEC/HPP blend 23.6 5.4
Example 3-2 SAPEC/HPP blend 22.0 2.4 Example 3-3 SAPEC/HPP blend
21.2 4.1 Example 4 Metallocene RCP 24.0 3.2 Example 5-1 Z-N RCP
24.0 3.0 Example 5-2 Z-N RCP 5.0 5.0 Example 6-1 Z-N ICP 7.5 9.0
ACHIEVE 3854 Metallocene HPP 24.0 0 Note: HPP is propylene
homopolymer
Example 7
Fabrication of Films
[0185] Cast monolayer films from most of the polymers in Table 6
were fabricated on a Killion cast coex film line. The line has
three 24:1 L/D extruders (`A` extruder at 1 inch or 25.4 mm
diameter; `B` extruder at 0.75 inch or 19.05 mm diameter; `C`
extruder at 0.75 inch or 19.05 mm diameter) which feed polymer into
a feedblock. For the monolayer films, only the `A` extruder was
used. The feedblock diverts molten polymer from each extruder to
specific channels. The combined streams enter an 8 inch (203.2 mm)
wide Cloeren die. Molten polymer exits the die and is cast onto a
chill roll (8 inch or 203.2 mm diameter and 10 inch or 254 mm roll
face). The film take-off unit is of adjustable speed, to obtain
films of different desired thicknesses. Typical line operating
conditions during the production of about 2 mil (50.8 .mu.m) films
are shown in Table 7. TABLE-US-00008 TABLE 7 Typical Killion Cast
Line Operating Conditions (2 mil or 50.8 .mu.m films) Zone 1
Temperature 390 F. (199 C.) Zone 2 Temperature 400 F. (204.5 C.)
Zone 3 Temperature 410 F. (210 C.) Adapter 1 Temperature 420 F.
(215.5 C.) Adapter 2 Temperature 420 F. (215.5 C.) Die/Feedblock
Temperature 430 F. (221 C.) Melt Temperature 396-400 F. range
(202-204.5 C.) Pressure 390-420 psi range (2.7 MPa-2.9 MPa)
Extruder Speed 45-58 rpm range Extruder Drive 2-2.5 amp range Line
Speed 10.8-11.6 fpm range (3.3-3.5 mpm) Chill Roll Temperature
58-64 F. range (14.5-17.8 C.) Film thickness 2.0-2.4 mil range
(50.8-61.0 .mu.m)
[0186] Film from ICP product Example 6-1 was fabricated on a
Black-Clawson cast film line. The line has two 3.5 inch (89 mm),
30/1 L/D extruders and one 2.5 inch (64 mm) 30/1 L/D extruder. The
flows from each extruder are combined in a three-layer Cloeren feed
block. In addition to monolayer film, various 3-layer film
constructions are possible. The die (Extrusion Dies Inc., Chippewa
Falls, Wis.) is 42 inch (106.7 cm) wide and utilizes a coat-hanger
design and an adjustable die lip. Die gaps of 15 to 20 mil (381 to
508 .mu.m) are typical. The casting section utilizes 30 or 36 inch
(76 to 91 cm) diameter primary chill rolls. With line speeds up to
1500 fpm (457 mpm), film thicknesses from 0.4 mil (10 .mu.m) to
upwards of 10 mil (254 .mu.m) are possible.
Example 8
Film Properties
[0187] Test methods for the different film properties are outlined
below. Film properties are generally identified with reference to
the film orientation (e.g. along the machine direction, MD; or
along the cross or transverse direction, TD). If a film property is
mentioned without identifying the related film direction, then i)
directionality is not relevant (e.g. puncture resistance) or ii)
the value is the average over the machine and transverse
directions. TABLE-US-00009 Test Test Method MD Ultimate Tensile
Strength, kpsi (MPa) ASTM D 882 TD Ultimate Tensile Strength, kpsi
(MPa) ASTM D 882 MD Elongation at Break, % ASTM D 882 TD Elongation
at Break, % ASTM D 882 MD Tensile Modulus, kpsi (MPa) ASTM D 882 TD
Tensile Modulus, kpsi (MPa) ASTM D 882 MD Elmendorf tear, g/mil
(g/.mu.m) ASTM D 1922, TD Elmendorf tear, g/mil (g/.mu.m) ASTM D
1922, Puncture Resistance, lb/mil (g/.mu.m) ASTM 5748-95* Puncture
Energy, in.lb/mil (J/.mu.m) ASTM 5748-95* Total energy impact,
ft.lb (J) ASTM D 4272-99 Haze, % ASTM D 1003 Gloss at 45 degree,
unit ASTM D 2457 *Puncture resistance and puncture energy testing
followed ASTM D 5748-95, but with the following exceptions: i.) A
0.75 inch diameter elongated stainless steel probe with matted
finish was used, instead of a 0.75 inch diameter pear-shaped
TFE-fluorocarbon coated probe. ii) An average gauge value measured
for the test sample was used as the gauge for all puncture
measurements on that sample, instead of measuring the gauge of each
sample specimen.
[0188] Optical properties of 2.0 mil (50.8 .mu.m) cast monolayer
films from the polymers and polymer blends in Table 6 are shown in
Table 8. All the films display low haze, but the films of Examples
3-1 and 3-3 appear to have the best clarity, even though they are
heterogeneous blend compositions without clarifying or nucleating
agents. Likewise, the gloss of these SAPEC blend films appears very
favorable. Film (about 2 mil or 50.8 .mu.m) mechanical properties
of these same polymers are shown in Table 9. TABLE-US-00010 TABLE 8
Cast Film Optical Properties Gloss Single Polymer Film thickness
haze at 45.degree. or Blend (mil/.mu.m) (%) (unit) Example 3-1
Heterogeneous blend 1.98/50.3 0.7 90.9 Example 3-2 Heterogeneous
blend 2.08/52.8 1.2 89.2 Example 3-3 Heterogeneous blend 1.98/50.3
0.5 90.8 Example 4 Single polymer 2.08/52.8 1.1 89.9 Example 5-1
Single polymer 2.3/58.4 1.2 88.4 ACHIEVE 3854 Single polymer
2.2/55.6 0.9 90.8
[0189] TABLE-US-00011 TABLE 9 Cast Film Mechanical Properties
[monolayer 2 mil or 50.8 .mu.m] Part 1 Ex 3-1 Ex-3-2 Ex 3-3 MD Ult
Tensile, kpsi (MPa) 6.3(43.5) 7.1(49) 6.4(44.2) TD Ult Tensile,
kpsi (MPa) 6.3(43.5) 6.9(47.6) 6.3(43.5) MD Break Elong, % 700 694
698 TD Break Elong, % 713 686 690 MD Ten Mod, kpsi (MPa) 40(276)
77(531) 45(311) TD Ten Mod, kpsi (MPa) 37(255) 69(476) 38(262) MD
Elmen tear, g/mil (g/.mu.m) 125(4.92) 40(1.57) 113(4.45) TD Elmen
tear, g/mil (g/.mu.m) 323(12.72) 38(1.50) 184(7.24) Puncture
Resist, lb/mil (g/.mu.m) 7.9(141.2) 8.9(159.1) 8.3(148.4) Punct
Energy, in.lb/mil (J/.mu.m) 28.5(0.13) 27.6(0.12) 26(0.12) Total
energy impact, ft.lb (J) >5.7(>7.7) 2.2(3.0) >5.7(>7.7)
Part 2 Achieve Ex 4 Ex 5-1 3854 MD Ult Tensile, kpsi (MPa)
6.3(43.5) 6.0(41.4) 7.7(53.1) TD Ult Tensile, kpsi (MPa) 6.0(41.4)
5.9(40.7) 7.2(49.7) MD Break Elong, % 675 668 698 TD Break Elong, %
656 672 686 MD Ten Mod, kpsi (MPa) 60(414) 64(442) 115(794) TD Ten
Mod, kpsi (MPa) 58(400) 61(421) 106(731) MD Elmen tear, g/mil
(g/.mu.m) 33(1.3) 29(1.14) 35(1.38) TD Elmen tear, g/mil (g/.mu.m)
36(1.42) 37(1.46) 36(1.42) Puncture Resist, lb/mil (g/.mu.m)
8.2(146.6) 8.7(155.5) 8.7(155.5) Punct Energy, in.lb/mil (J/.mu.m)
24.2(0.11) 26.6(0.12) 23.1(0.10) Total energy impact, ft.lb (J)
2.4(3.3) 2.7(3.7) 1.8(2.44)* *Dart impact (ASTM D-1709; 26 in or 66
cm drop height) for ACHIEVE 3854 film is 47 g/mil (1.85
g/.mu.m)
[0190] Blend films, Ex 3-1,3-2 and 3-3, show superior tear
resistance (Elmendorf tear test; ASTM D1922), particularly along
the machine direction. Elmendorf tear resistance is not usually a
strength for polypropylene films. The values shown by the ACHIEVE
3854 and Ex 5-1(Ziegler-Natta RCP) controls (about 30 to 35 g/mil
along the machine direction) are typical numbers for cast
polypropylene films. Against this background, the inventive blend
films values of >100 g/mil MD tear resistance were quite
unexpected. The inventive films also display outstanding impact
strength (total energy impact as measured by a Kayeness total
energy impact tester; ASTM D 4272-99), again superior to that of
the controls (Ex 5-1 and ACHIEVE 3854). Additionally, the films
show favorable tensile properties (ASTM D882) including low film
stiffness.
[0191] The blend films are compared against Example 5-2 film in
Table 10. Example 5-2 (5 MFR, 5 wt % ethylene) is another
Ziegler-Natta-based RCP, like Example 5-1, but contains a higher
level of ethylene comonomer. TABLE-US-00012 TABLE 10 Cast Film
Mechanical Properties [monolayer films] Ex 3-1 Ex 5-2 (5.4 wt %
ethylene) (5 wt % ethylene) Film thickness, mil (.mu.m) 1.98 (50)
1.77 (45) MD Ult Tensile, kpsi (MPa) 6.3 (43.5) 7.5 (51.8) TD Ult
Tensile, kpsi (MPa) 6.3 (43.5) 6.4 (44.2) MD Break Elong, % 700 624
TD Break Elong, % 713 643 MD Ten Mod, kpsi (MPa) 40 (276) 57 (393)
TD Ten Mod, kpsi (MPa) 37 (255) 57 (393) MD Elmen tear, g/mil
(g/.mu.m) 125 (4.92) 53.3 (2.1) TD Elmen tear, g/mil (g/.mu.m) 323
(12.72) 180 (7.1) Puncture Resist, lb/mil (g/.mu.m) 7.9 (141.2) 6.3
(112.6) Punct Energy, in.lb/mil (J/.mu.m) 28.5 (0.13) 14.3 (0.06)
total energy impact, ft.lb (J) >5.7 (>7.7) -- haze, % 0.7 3.1
Gloss at 45.degree., unit 90.9 77.8
[0192] From the data in Table 10 it is seen that even at matching
total ethylene content, the blend film is more machine direction
tear resistant. The inventive blend films, despite being
heterogeneous in composition versus random copolymers, show an
unexpected favorable properties profile of low haze, high tear
resistance, high impact resistance and comparatively low stiffness.
The film properties of a Ziegler-Natta impact copolymer would be
representative of standard, heterogeneous propylene copolymers.
Example 6-1, PP7623 E7, was cast into film on the Black-Clawson
cast film line. The film properties are TABLE-US-00013 TABLE 11
Cast Film Mechanical Properties [monolayer film] Example 6-1
(PP7623 E7 Impact Copolymer) Film thickness, mil (.mu.m) 4.2
(106.7) MD Ult Tensile, kpsi (MPa) 5.9 (40.7) TD Ult Tensile, kpsi
(MPa) 5.6 (38.9) MD Break Elong, % 727 TD Break Elong, % 720 MD Ten
Mod, kpsi (MPa) 82 (566) TD Ten Mod, kpsi (MPa) 79 (545) MD Elmen
tear, g/mil (g/.mu.m) 63.6 (2.5) TD Elmen tear, g/mil (g/.mu.m)
81.4 (3.2) Dart Impact (F.sub.50; 20 in drop), g/mil (g/.mu.m) 152
(6.0) Total haze, % 77 Internal haze*, % 13 Gloss at 45.degree.,
unit 6.5 *Internal haze is the haze excluding any film surface
contribution. The film surfaces are coated with ASTM approved inert
liquids to eliminate any haze contribution from the film surface
topology. The haze measurement procedure is per ASTM D 1003.
From the data in Table 11, the heterogeneous Example 6-1 polymer is
defensive to the heterogeneous inventive blends with regard to film
tear resistance and clarity.
[0193] In the literature, Catalloy-based multi-phase Ziegler-Natta
propylene polymers were shown to have high tear strength
(particularly MD tear resistance). Data can be found in P. Galli's
literature article "The Future Role of Ziegler-Natta Catalysts
(In-situ Flexible Polyolefinic Alloys)", Proceedings of FLEXPO '96,
Houston, Tex., p 113-152, which is incorporated by reference. Data
on cast monolayer film from the propylene polymer identified as
Adflex.TM. C 200 F were presented in Table 9 of the referenced
literature article. A segment of this data containing the cast film
properties on Adflex C 200 F is reproduced in Table 12 below. The
only change made to the original data in Table 9 of the referenced
literature article is the inclusion of English and/or metric unit
values, corresponding to the SI units used in the original table.
TABLE-US-00014 TABLE 12 Monolayer Cast Film Properties on Adflex C
200 F as reported in Proceedings of FLEXPO '96, Houston, TX, p
113-152 Total thickness, .mu.m (mil) 25(1) Puncture, max str. 23 C,
N (g) 3.3(337) Puncture, deflect. 23 C, cm (inch) 1.9(0.75) Dart
drop (66 cm), g >1500 haze, % 21 MD TD Tensile Modulus, MPa
(kpsi) 80(11.6) 65(9.4) Stress at yield, MPa (kpsi) 6.3(0.91)
5.0(0.72) Elong. at yield, % 18 17 Stress at break, MPa (kpsi)
32(4.6) 21(3.0) Elong. at break, % 700 790 Elmendorf tear str., N
(g) 2.5(255) 3.5(357) Elmendorf tear str., N/.mu.m (g/mil) 0.1(255)
0.14(357)
[0194] Adflex C 200 F is a 6 MFR heterogeneous impact copolymer
from Basell Polyolefins, Hoofddorp, The Netherlands. The data in
Table 12 show the film to be very low in stiffness, suggesting a
composition with a significant level of copolymer rubber. While the
monolayer film has outstanding tear resistance and impact
resistance and good softness (ie. very low film modulus), the film
haze is quite high (greater than 20%). On balance, it does not
possess the properties profile of low haze, high tear resistance,
high impact resistance and comparatively low stiffness of the
heterogeneous SAPEC blend examples.
[0195] All patents and patent applications, test procedures (such
as ASTM methods), and other documents cited herein, including
priority documents, are fully incorporated by reference to the
extent such disclosure is not inconsistent with this invention and
for all jurisdictions in which such incorporation is permitted.
When numerical lower limits and numerical upper limits are listed
herein, ranges from any lower limit to any upper limit are
contemplated.
* * * * *